Ear Warmer Having A Curved Ear Portion

ABSTRACT

An ear warmer comprises a frame disposed within a cavity of a shell. The frame includes a band portion and an ear portion. The ear portion includes an inner side disposed adjacent a head of a user when the ear warmer is worn by a user. In one embodiment, the ear portion is curved toward the inner side of the ear portion. In one embodiment, the ear portion is configured to flex when the ear warmer is disposed on a head of a user.

CROSS-REFERENCE TO OTHER APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/693,607, entitled “Ear Warmer Having a Curved Ear Portion,” filedOct. 27, 2003, which is a continuation-in-part of U.S. patentapplication Ser. No. 10/638,476, entitled “Ear Warmer Having An ExternalFrame,” filed Aug. 12, 2003, now U.S. Pat. No. 7,650,649, the disclosureof each of which is incorporated herein by reference in its entirety.Additionally, this application is related to U.S. patent applicationSer. No. 10/638,554, entitled “Ear Warmer Having a Membrane Forming aReceptacle,” filed Aug. 12, 2003, now U.S. Pat. No. 7,222,373; and U.S.patent application Ser. No. 10/638,553, entitled “Ear Warmer With aSpeaker System,” filed Aug. 12, 2003, now U.S. Pat. No. 7,212,645;the-disclosure of each of which is incorporated herein by reference inits entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to ear warmers, and in particular toear warmers that have a frame and are configured to extend around a backof a user's head.

Conventional ear warmers extend over a top of a user's head. Such aconventional ear warmer typically has a frame and a layer of fabric oneach side of an ear portion of the frame. These layers of fabric and theframe itself typically have a weight appropriate for sedentaryoutdoor-activities, but not for non-sedentary outdoor-activities such asrunning or jogging. In other words, when participating in certainoutdoor activities, the participant desires apparel that keeps him orher warm while minimizing the weight of such apparel. While capable ofkeeping the user warm, conventional ear warmers do not have such desiredminimal weight.

Thus, a need exists for an ear warmer that is lightweight while stillproviding warmth to the user.

SUMMARY OF THE INVENTION

An ear warmer comprises a frame disposed within a cavity of a shell. Theframe includes a band portion and an ear portion. The ear portionincludes an inner side disposed adjacent a head of a user when the earwarmer is worn by a user. In one embodiment, the ear portion is curvedtoward the inner side of the ear portion. In one embodiment, the earportion is configured to flex when the ear warmer is disposed on a headof a user.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an ear warmer in an expandedconfiguration according to an embodiment of the invention.

FIG. 2 is a front perspective view of the frame of the ear warmerillustrated in FIG. 1.

FIG. 3 is a front view of the frame of the ear warmer illustrated inFIG. 2.

FIG. 4 is a rear view of the frame of the ear warmer illustrated in FIG.2.

FIG. 5 is a top view of the frame of the ear warmer illustrated in FIG.2.

FIG. 6 is a bottom view of the frame of the ear warmer illustrated inFIG. 2.

FIG. 7 is a right side view of the frame of the ear warmer illustratedin FIG. 2.

FIG. 8 is left side view of the frame of the ear warmer illustrated inFIG. 2.

FIG. 9 is a rear perspective view of the frame of the ear warmerillustrated in FIG. 2.

FIG. 10 is a perspective view of the frame of the ear warmer illustratedin FIG. 2 in a collapsed configuration.

FIG. 11 is a top view of the frame of the ear warmer illustrated in FIG.2 in a collapsed configuration.

FIG. 12 is a side view of the frame of the ear warmer illustrated inFIG. 2 in a collapsed configuration.

FIG. 13 is a perspective view of an ear portion of the frame of the earwarmer illustrated in FIG. 2.

FIG. 14 is a top view of the ear portion illustrated in FIG. 13.

FIG. 14A is a front perspective view of the ear portion illustrated inFIG. 13.

FIG. 15 is a front view of the ear portion illustrated in FIG. 13.

FIG. 16 is a rear view of the ear portion illustrated in FIG. 13.

FIG. 17 is a perspective view of a band portion of the frame of the earwarmer illustrated in FIG. 2.

FIG. 18 is a top view of the band portion illustrated in FIG. 17.

FIG. 19 is a bottom view of the band portion illustrated in FIG. 17.

FIG. 20 is a front view of the band portion illustrated in FIG. 17.

FIG. 21 is a side view of the band portion illustrated in FIG. 17.

FIG. 21A is a perspective view of an alternative embodiment of a bandportion of a frame according to an embodiment of the invention.

FIG. 21B is a top view of an alternative embodiment of a band portion ofa frame according to an embodiment of the invention.

FIGS. 22-23 are perspective views of frames according other embodimentsof the invention.

FIG. 24 is a side view of an ear portion according to another embodimentof the invention.

FIG. 25 is a side view of an ear portion according to another embodimentof the invention.

FIG. 26 is a side view of a portion of an ear warmer according to anembodiment of the invention.

FIGS. 26A and 26B are partial cross-sectional views of an embodiment ofa portion of an ear warmer according to an embodiment of the invention.

FIGS. 27 and 28 are a side view and cross-section view along line 28-28,respectively, of a portion of an ear warmer having a press-fitconnection, according to an embodiment of the invention.

FIGS. 27A and 27B are a side view and cross-section view along line27B-27B, respectively, of a portion of an ear warmer having a press-fitconnection, according to an embodiment of the invention.

FIGS. 28A and 28B are a side view and cross-section view along line28B-28B, respectively, of a portion of an ear warmer having a press-fitconnection, according to an embodiment of the invention.

FIG. 28C is a perspective view of an ear warmer having a clip-onconnection, according to an embodiment of the invention.

FIG. 28D is a side view of a portion of the ear warmer of FIG. 28C.

FIG. 28E is a cross-section view taken along line 28E-28E of the earwarmer of FIG. 28C.

FIGS. 28F and 28G are cross-section views of an ear warmer having aclip-on connection, according to an embodiment of the invention.

FIGS. 29 and 30 are a side view and cross-section view along line 30-30,respectively, of a portion of an ear warmer having a press-fitconnection, according to another embodiment of the invention.

FIGS. 31 and 32 are a side view and cross-section view along line 32-32,respectively, of a portion of an ear warmer having a tongue-and-grooveconnection, according to an embodiment of the invention.

FIG. 33 is a side view of a portion of an ear warmer having a clip-onconnection, according to an embodiment of the invention.

FIG. 34 is a side view of a portion of an ear warmer having a fabricmember, according to an embodiment of the invention.

FIG. 35 is a side view of a portion of an ear warmer having a fabricmember, according to another embodiment of the invention.

FIG. 36 is a side view of a portion of an ear warmer having a fabricmember, according to another embodiment of the invention.

FIG. 37 is a side view of a portion of the ear warmer having a fabricmember, according to another embodiment of the invention.

FIG. 38 is a perspective assembly view of the portion of the ear warmershown in

FIG. 37.

FIG. 39 is a perspective view of a portion of an ear warmer having afabric member covering at least a portion of the inner side of theframe, according to an embodiment of the invention.

FIG. 40 is a perspective view of a portion of an ear warmer having afabric member covering at least a portion of the inner side of theframe, according to another embodiment of the invention.

FIG. 41 is a perspective view a portion of an ear warmer having a fabricmember and a support member, according to another embodiment of theinvention.

FIG. 42 is a perspective view of a frame of an ear warmer according toan embodiment of the invention.

FIG. 43 is a rear view of the frame illustrated in FIG. 42.

FIG. 44 is a front view of the frame illustrated in FIG. 42.

FIG. 45 is a right side view of the frame illustrated in FIG. 42.

FIG. 46 is left side view of the frame illustrated in FIG. 42.

FIG. 47 is a top view of the frame illustrated in FIG. 42.

FIG. 48 is a bottom view of the frame illustrated in FIG. 42.

FIG. 49 is a side view of a ear warmer being worn by a user according toan embodiment of the invention.

FIG. 50 is a perspective view of a frame of an ear warmer according toan embodiment of the invention.

FIG. 51 is a perspective view of an ear portion of the frame illustratedin FIG. 50.

FIG. 52 is a rear view of the ear portion illustrated in FIG. 51.

FIG. 53 is a front view of the ear portion illustrated in FIG. 51.

FIG. 54 is an outer side view of the ear portion illustrated in FIG. 51.

FIG. 55 is an inner side view of the ear portion illustrated in FIG. 51.

FIG. 56 is a top view of the ear portion illustrated in FIG. 51.

FIG. 57 is a bottom view of the ear portion illustrated in FIG. 51.

FIG. 57A is a perspective view of an ear portion for a frame of an earwarmer according to an embodiment of the invention.

FIG. 57B is top view of the ear portion illustrated in FIG. 57A.

FIG. 58 is a top view of the band portion of the frame illustrated inFIG. 50.

FIG. 59 is a top view of a member of the band portion illustrated inFIG. 58.

FIG. 60 illustrates a set of membranes for use in constructing a shellof an ear warmer according to an embodiment of the invention.

FIG. 61 illustrates an arrangement of the ear warmer shell of FIG. 60during an interim step in an assembly process.

FIG. 62 illustrates a cross-sectional view of the ear warmer shell ofFIG. 61 taken along the lines “62-62” in FIG. 61.

FIG. 63 illustrates an arrangement of an ear warmer shell according toan embodiment of the invention.

FIG. 64 illustrates a cross-sectional view of the ear warmer shell ofFIG. 63 taken along the lines “64-64” in FIG. 63.

FIG. 65 illustrates a set of membranes for use in constructing anothershell for an ear warmer according to an embodiment of the invention.

FIG. 66 illustrates a membrane for use in constructing another shell foran ear warmer according to an embodiment of the invention.

FIG. 67 illustrates a membrane for use in constructing another shell foran ear warmer according to an embodiment of the invention.

DETAILED DESCRIPTION

An ear warmer comprises a frame and a fabric member. The frame has anear portion and a band portion. The ear portion of the frame includes afirst side and a second side opposite the first side. The first side ofthe ear portion defines an interior portion of an opening. The secondside of the ear portion defines an exterior portion of the opening. Thefabric member includes at least its own ear portion coupled to a portionof the frame. In one embodiment, the ear portion of the fabric membercovers the interior portion of the opening in substantially itsentirety. In one embodiment, the ear portion of the fabric member coversless than an entirety of the exterior portion of the opening. The term“less than an entirety” should be understood to mean that the fabricmember covers some of the exterior portion of the opening or none of theexterior portion of the opening.

In one embodiment, an ear warmer comprises a frame disposed within acavity of a shell. The frame includes a band portion and an ear portion.The ear portion includes an inner side disposed adjacent a head of auser when the ear warmer is worn by a user. In one embodiment, the earportion is curved toward the inner side of the ear portion. In oneembodiment, the ear portion is configured to flex when the ear warmer isdisposed on a head of a user.

An ear warmer 100 according to an embodiment of the invention isillustrated in FIG. 1. In this embodiment, the ear warmer 100 includes aframe 110 and two fabric members 230 and 250. The ear warmer 100 isdisposable in an expanded configuration and in a collapsedconfiguration. The frame 110 of the ear warmer 100 includes a first earportion 130, a second ear portion 190 and a band portion 200. In thisembodiment, fabric member 250 is coupled to the first ear portion 130.Similarly, fabric member 230 is coupled to the second ear portion 190.The fabric members 230 and 250 can be fixedly or removably coupled tothe respective ear portions. Various techniques for coupling of thefabric members 230 and 250 are discussed below in detail.

In an alternative embodiment, the frame 110 can be a single piece ofmaterial in which the first ear portion 130, the second ear portion 190and the band portion 200 are formed monolithically (i.e., unitaryconstruction). In another embodiment, the band portion 200 can beadjustable in length. In another embodiment, the first ear portion 130and the second ear portion 190 can be fixedly coupled to the bandportion 200.

An embodiment of a single-piece frame is illustrated in FIG. 22. In thisembodiment, the frame 270 includes a band portion 272, a first earportion 274 and a second ear portion 276. The first ear portion 274 andthe second ear portion 276 are not collapsible with respect to the bandportion 272. The frame 270 can have an expanded configurationcorresponding to a position on the user's head and an unexpandedconfiguration corresponding to a position off the user's head. The frame270 can have an inward bias that defines the unexpanded configuration.Although the user's head is not shown, FIG. 22 shows the frame 270 inthe expanded configuration. In alternative embodiments, the position ofear portions 274 and 276 in the expanded and unexpanded configurationscan differ from that shown in FIG. 22.

An embodiment of an alternative frame is illustrated in FIG. 23. In thisembodiment, the frame 280 has unitary construction including a bandportion 284, a first ear portion 286 and a second ear portion 288. Thefirst ear portion 286 has an end portion 287 that couples to the bandportion 284. The second ear portion 288 has an end portion 289 thatcouples to the band portion 284. In this embodiment, the ends 287 and289 are wrapped around the band portion 284.

FIGS. 2 through 9 illustrate the frame 110 of the ear warmer 100 in anexpanded configuration. FIGS. 10 through 12 illustrate the frame 110 ofthe ear warmer 100 in a collapsed configuration. The frame 110 includesa band portion 200, a first ear portion 130 coupled to the band portion200, and a second ear portion 190 coupled to the band portion 200.

As illustrated in FIGS. 2 through 9 and 17 through 21, the band portion200 is configured to extend around the back of a user's head. The bandportion 200 includes a middle portion 203, a first end portion 202, anda second end portion 204. The band portion 200 has an inner side 206(the side that is disposed adjacent a user when the ear warmer is wornby the user), an outer side 208 (the side opposite the inner side anddistal from a user when the ear warmer is worn by the user), an upperside 210 (the side that faces up when the ear warmer is worn by a user),and a lower side 212 (the side that faces down when the ear warmer isworn by a user).

In one embodiment the band portion 200 varies in a height dimension andhas a substantially tapered shape (see FIG. 4). As illustrated in FIG.4, the middle portion 203 of the band portion 200 is of a lesser heightor thickness than either of the first end portion 202 of the bandportion 200 and the second end portion 204 of the band portion 200. Inan alternative embodiment, the band portion 200 has a constant height orthickness.

Referring to FIGS. 17-21, the first end portion 202 of the band portion200 includes a first coupling portion 218 configured to be coupled tothe first ear portion 130 of the frame 110. Similarly, the second endportion 204 of the band portion 200 includes a second coupling portion220 configured to be coupled to the second ear portion 190 of the frame110. In this embodiment, the first coupling portion 218 and the secondcoupling portion 220 are substantially similar in function and structurewith the exception that they are reverse images of each other.Therefore, only the first coupling portion 218 of the band member 200will be discussed in detail. In alternative embodiments, the couplingportions may have different configurations and/or structures.

As illustrated in FIGS. 17 and 18, the first coupling portion 218includes an end surface 214 of the band portion 200 and includes distalend 222. The distal end 222 of the first coupling portion 218 has amounting structure and defines a planar surface (also referred to hereinas the “oblique plane”). Although in one embodiment the mountingstructure is cylindrical in shape, the mounting structure need not becylindrical in shape. The coupling portion and mounting structure may beof any shape, such as cubic or rectangular.

Referring to FIG. 20, the oblique plane is oblique to the surfacesdefined by the upper side 210 and lower side 212 of the band portion200. Additionally, as illustrated in FIG. 19, the oblique plane isoblique to the surfaces defined by the inner side 206 proximate thecoupling portion 218 and the outer side 208 of the band portion 200proximate the coupling portion 218.

In one embodiment, the oblique plane enables the ear portion to moveupwardly and inwardly to a collapsed configuration as described below.In an alternative embodiment, the end surface of the band portion is atan oblique plane with respect to only one side of the band portion.Alternatively, the end surface of the band portion can be substantiallyperpendicular to the outer surface of the band portion.

In one embodiment, the frame, including the band portion and the earportions, is made of a single material. In another embodiment, the frameis made of polypropylene. In alternative embodiments, the frame is madeof a thermoplastic resin material, such as Crastin® sold by DuPont, orGrillamid®.

In an alternative embodiment, the band portion 200 includes a recess 207(see FIG. 17). In this embodiment, the band portion 200 is made of afirst material 201 and a second material 219 (see FIG. 17). The secondmaterial 219 may be any material that increases friction contact. Also,the second material 219 can be any material that can distribute theforce of the ear warmer 100 when retained on the user. In the embodimentshown in FIG. 17, the second material extends for less than the entireheight of the band portion. In alternative embodiments, the secondmaterial can be on the inside of the band portion only, the inside andoutside of the band portion, or the outside of the band portion only.Alternatively, the second material can be disposed in two or moreseparate locations on the band portion. In an alternative embodiment,the second material extends across an entire width of the band portion.In one embodiment, the first material 201 is a plastic material and thesecond material 219 is a rubber material. Although the band portion ofthe frame is illustrated as being elongated, the band portion need notbe elongated in shape.

Referring to FIG. 17, the coupling portion 218 is illustrated anddescribed in detail. In this embodiment, the coupling portions 218 and220 are substantially the same. Accordingly, only coupling portion 218is described in detail. It is to be understood that alternativeembodiments of the band portion to not necessarily need to have all ofthe features and/or structures discussed with respect to couplingportion 218. In other words, alternative coupling portions can have anycombination of the structures.

Referring to FIG. 17, the coupling portion 218 includes a mountingstructure 218 a that in substantially cylindrical in shape. The mountingstructure 218 a has a lower surface that can include one or morerecesses or notches 218 d, the function of which is described later. Themounting structure 218 a also includes a center shoulder 218 b that hasan opening 218 c that is configured to receive a connector, such as ascrew.

In one embodiment, the end of the band portion 200 includes a first endsurface 221 a and a second end surface 221 b that is proximate tosurface 221 a. The surfaces 221 a and 221 b are offset and at an anglewith respect to each other. The configuration of surfaces 221 a and 221b assist with the movement of the ear portion with respect to the bandportion. In an alternative embodiment, surfaces 221 a and 221 b aredisposed in the same plane. As described below, surfaces 221 a and 221 bform contact surfaces that limit the rotation of the ear portionrelative to the band. The end of the band portion 200 also includesanother surface 221 a and a shoulder 221 d adjacent surface 221 c. Thesurface 221 c and shoulder 221 d form an abutment that is contacted bythe ear portion to limit the rotation of the ear portion with respect tothe band portion 200. In an alternative embodiment, the band portiondoes not include a surface and shoulder as previously described.

In one embodiment, the band portion includes a coupler that isconfigured to removably couple a label, such as a brand label, to theband portion. In one embodiment, the coupler is disposed at the rear ofthe band portion. In alternative embodiments, the coupler is disposed ona side of the band portion, for example near the portion of the band,which couples to the ear portion, or at any other location on the bandportion.

An alternative embodiment of the band portion is illustrated in FIGS.21A and 21B. In this embodiment, a band portion 200′ includes supportmembers 202′ disposed on the inner surface 204′ of the band portion200′. Support members 202′ are configured to provide added strength andsupport to the band portion 200′.

An embodiment of an ear portion is illustrated in FIGS. 13-16. In thisembodiment, the first ear portion 130 of the frame 110 and the secondear portion 190 of the frame 110 are substantially similar in functionand structure. Therefore, only the first ear portion 130 is discussed indetail.

As illustrated in FIGS. 13 through 16, the first ear portion 130 of theframe 110 defines an opening 134 and a center point 152. The first earportion 130 includes a proximal end portion 156, which includes aproximal end point 136 (the portion and point being proximate to thecoupling of the first ear portion 130 and the band portion 200); adistal end portion 158, which includes a distal end point 138 (theportion and point being distal from the coupling of the first endportion 130 and the band portion 200); an uppermost portion 160, whichincludes an uppermost point 140 (the portion and point being uppermostwhen the ear warmer is disposed in an expanded configuration on a user);and a lowermost portion 162, which includes a lowermost point 142 (theportion and point being lowermost when the ear warmer is disposed in anexpanded configuration on a user).

Although points on the first ear portion 130 have been identified asbeing proximal, distal, uppermost, and lowermost, it should beunderstood that there may be, for example, several uppermost points ofthe first ear portion. In such a case, the “uppermost point” includesthe several points. The same is true for the proximal, distal, andlowermost points. In addition, the terms proximal, distal, uppermost,and lowermost are used for convenient reference with respect to theorientation shown in FIGS. 2 through 9 and 13 through 16. It should beunderstood that these locations of the frame are still applicableregardless of the orientation of the frame at any given time.

As illustrated in FIGS. 13 and 15, a portion 137 of the first earportion 130 of the frame 110 is disposed between the proximal end point136 and the uppermost point 140 and has a first part 137′ and a secondpart 137″. From a side view of the first ear portion 130 (see FIG. 13),the first part 137′ of the portion 137 has a convex configuration withrespect to the center point 152. Similarly, a portion 143 of the firstear portion 130 of the frame 110 is disposed between the lowermost point142 and the proximal end point 136. The portion 143 has a first part143′ and a second part 143″. From a side view, the first part 143′ ofthe portion 143 has a convex configuration with respect to the centerpoint 152. In other words, at least a portion of each of the portions137 and 143 of the first ear portion 130 bend or curve away from thecenter point 152. The location and number of inflection points inportions 137 and 143 can vary along the ear portion.

From a side view of the first ear portion 130, the portion 139 of thefirst ear portion 130 of the frame 110 that is disposed between theuppermost point 140 and the distal end point 138 has a concaveconfiguration with respect to the center point 152. Similarly, theportion 141 of the first ear portion 130 of the frame 110 that isdisposed between the distal end point 138 and the lowermost point 142has a concave configuration with respect to the center point 152. Inother words, at least a portion of each of the portions 139 and 141 ofthe first ear portion 130 bend toward the center point 152. Inalternative embodiments one or both of the portions 139 and 141 caninclude a concave portion or section and a convex portion or section,relative to the center point.

Referring to FIG. 14, the first ear portion 130 includes an inner side144 (the side that is disposed adjacent a user when the ear warmer isworn by the user), an outer side 146 (the side opposite the inner sideand distal from a user when the ear warmer is worn by the user), anupper side 148 (the side that faces up when the ear warmer is worn by auser), and a lower side 150 (see FIG. 13) (the side that faces down whenthe ear warmer is worn by a user). The inner side 144 of the first earportion 130 defines an interior portion or region of the opening 134.Similarly, the outer side 146 of the first ear portion 130 defines anexterior portion or region of the opening 134.

As illustrated in FIG. 14, the inner side 144 of the first ear portion130 of the frame 110 has an innermost surface 154. The innermost surface154 is the portion of the inner side 144 of the first ear portion 130directly adjacent a user's head when the ear warmer 100 is worn by theuser. Referring to FIG. 14, a top view of a two-dimensional projectionof the innermost surface 154 is a curved line that curves around a pointA, which is disposed on the inner side of the first ear portion 130. Inother words, the first ear portion 130 is curved such the distal endportion 158 is configured to be disposed closer to a user's head, or toplace more pressure on the user's head (if the entire portion of theframe is contacting the user's head), than a mid-point of the innermostsurface 154 when the ear warmer 100 is worn by the user. This is due tothe fact that the curvature of the user's head may be different from thecurvature of the ear portion. Said another way, the frame 110 isconfigured to apply lateral forces to the user's head inwardly where theforces are greatest at the distal end portion 158.

In one embodiment, the distal end portion 158 of the frame 110 isflexible. Thus, the lateral force of the distal end portion 158 againsta user's head causes the distal end portion to bend or flex and, thus,to better fit along the user's head. In an alternative embodiment, thefirst ear portion is curved such that the distal end portion of thefirst ear portion is configured to be disposed closer to a user's headthan the proximal end portion of the first ear portion when the earwarmer is worn by the user. In a further alternative embodiment, theportion of the innermost surface disposed between the proximal endportion and the distal end portion does not have a curved shape.

As illustrated in FIG. 14 a, a two-dimensional projection of a frontview of the innermost surface 154 is a curved line that has three radiiof curvature. Specifically, the two dimensional projection has a firstpart that bends or curves around point B, a second part that bends orcurves around part C, and a third part that bends or curves around pointD.

In the illustrated embodiment, the distal end portion 138 is curved suchthat a center portion of the distal end portion 138 is configured to bedisposed closer to a user's head than the remaining portions of thedistal end portion 138 when the ear warmer is worn by a user. In analternative embodiment, the uppermost portion is configured to bedisposed closer to the user's head than the lowermost portion when theear warmer is worn by the user. In a further alternative embodiment, thefirst ear portion is curved such that the lowermost portion isconfigured to be disposed closer to the user's head than the uppermostportion when the ear warmer is worn by the user.

Although the first ear portion 130 is described and illustrated ashaving a particular shape, in other embodiments, the first ear portionhas different shapes. Additionally, in one embodiment, the first earportion is made of a plastic material. In an alternative embodiment, thefirst ear portion is made of another material, such as a metal.

The first ear portion 130 has an abutting and complimentary fit with theband portion 200. More specifically, returning to FIG. 13, the first earportion 130 includes coupling portion 164 that extends from an endsurface 166 of the first ear portion 130. The coupling portion 164includes a distal end 165 that defines a surface 165 a. In oneembodiment, the surface 165 a includes one or more ridges or protrusions165 b that engage the recesses 218 d as the ear portion rotates. Thecoupling portion 164 is received in structure 218 a. In one embodiment,the end portion of the first ear portion 130 includes surfaces 167 a and167 b that compliment and engage surfaces 221 a and 221 b on the bandportion 200 when the ear portion 130 is in its collapsed configuration.The end portion also includes a protrusion 167 c with a contact surface167 d that engages the surface 221 c and shoulder 221 d to form asecondary stop to limit the rotation of the ear portion. In alternativeembodiments, the ear portion does not include protrusion 167 c and bandportion 200 does not include the surface 221 c and shoulder 221 d. Asillustrated in FIG. 20, the surface defined by the distal end 222 of thecoupling portion 218 of the band portion 200 abuts the surface definedby the distal end 165 of the coupling portion 164. Also, the end surface214 of the band portion 200 of the frame 110 abuts the end surface 166of the first end portion 130. In other words, the band portion 200 abutsthe first ear portion 130 and has surfaces, including the surfacedefined by the distal end 222 of the coupling portion 218 and the endsurface 214 of the band portion 200, that fit complimentary to surfacesof the first end portion 130, including the surface defined by thedistal end 165 of the coupling portion 164 and the end surface 166 ofthe first ear portion 130, when the first ear portion 130 is in itscollapsed configuration.

Because of abutting and complimentary fit of the band portion 200 andthe first ear portion 130, the transition between the outer surface 208of the band portion 200 and the outer surface 146 of the first earportion 130 is a smooth transition or a substantially smooth transition.In other words, the outer surface 208 of the band portion 200 and theouter surface 146 of the first ear portion 130 form a substantiallycontinuous surface when the ear warmer is in the expanded configuration.With the exception of the inner surface, the same is true for theremaining surfaces of the band portion 200 and the first ear portion130. Specifically, the upper surface 210 of the band portion 200 and theupper surface 148 of the first ear portion 130 form a substantiallycontinuous surface. The lower surface 212 of the band portion 200 andthe lower surface 150 of the first ear portion 130 form a substantiallycontinuous surface.

In one embodiment, the coupling portions of the ear portion and the bandportion is located on the inner surface. In an alternative embodiment,the inner surface of the ear portion and the inner surface of the bandportion form a substantially continuous surface. Alternatively, thecoupling portions of the band portion and the ear portion are located atdifferent locations.

The substantially continuous surface formed by the upper surface 210 ofthe band portion 200 and the upper surface 148 of the first ear portion130 extends from the first ear portion 130 to the second ear portion190. The substantially continuous surfaces formed by the lower, upper,and inner surfaces of the band portion 210 and the first ear portion 130also extend to the respective surfaces of the second ear portion. Thus,the upper surface of the ear warmer 100, the lower surface of the earwarmer 100, and the outer surface of the ear warmer 100 collectivelyform a smooth contour. In alternative embodiments any combination of thecorresponding surface, outer surface, upper surface and lower surface ofany of the frame components can form a substantially continuous surface.

In one embodiment, a screw (not illustrated) is used to pivotally couplethe first ear portion 130 to the band portion 210. A first end of thescrew extends from the inner side 144 of the first ear portion 130 and asecond end of the screw is disposed within the band portion 200 and isnot outwardly visible. In other words, only a single end of the screw isexposed (i.e., disposed outside of the frame 110 of the ear warmer 100).In alternative embodiments, a rivet, a pin, a brad, or any othercoupling device is used to pivotally couple the ear portions 130 and 190to the band portion 200.

FIGS. 10 though 12 illustrate the frame 110 of the ear warmer 100 in acollapsed configuration. The first ear portion 130 and the second earportion 190 are disposed adjacent to and substantially within the sameplane as the band portion 200 when the frame 110 is in its collapsedconfiguration. The coupling arrangement between the band portion 200 andthe ear portions (as described in detail above) allow the ear portions130 and 190 to pivot into and out of the collapsed configuration. Asillustrated in FIG. 12, the ear warmer 100 has a low profile when in itscollapsed configuration. In one embodiment, the oblique plane defined bythe band portion 200 allows the ear portion 130 and 190 to move in a waythat contributes to this overall low profile. For example, the obliqueplane allows the ear portions to rotate about the pivot connection whilebeing substantially within or proximate the same plane as the bandportion 200.

Ear warmer 100 is configured to allow a predetermined range of motionbetween the expanded configuration and the collapsed configuration. Inone embodiment, this range of motion does not include movement from theexpanded configuration to a different collapsed configuration, forexample, where the ear portions of the frame are disposed on a side ofthe band opposite from their position in the collapsed configurationwithin the range of motion. In one embodiment, two different mechanismseach produce a respective stop that defines a respective end point ofthe range of motion (as discussed below).

In an alternative embodiment, the ear portions can rotate continuouslyand are not limited to a particular range. Alternatively, the earportions can be slidably coupled to the band portion, or can rotateabout another axis than that described above.

As illustrated in FIGS. 22 and 23, it is not necessary that the frame beseparate items. In FIGS. 22 and 23, the frames 270 and 280,respectively, are of a unitary or monolithic structure. In theseembodiments, the band portions 272 and 286, respectively, do not haveadjustable lengths. In a further alternative embodiment, the bandportion is an adjustable band. In yet a further alternative embodiment,the band portion of the frame includes several different and separateitems.

Alternative embodiments of ear portions are illustrated in FIGS. 24 and25. In these embodiments, the ear portions may be formed of a firstmaterial and a second material that is different than the firstmaterial. In FIGS. 24 and 25, the ear portions 290 and 291,respectively, are made of a first material 292 and a second material294. For example, the first material 292 may be any type of plastic andthe second material 294 may be any type of resilient material, such asrubber. The resilient material 294 provides for an increased grippingsurface for contact with the user or other article. The resilientmaterial 294 also increases the distribution of the application ofclamping or gripping force of the ear warmer on the user's head. In FIG.24, the second material extends an entire width of a portion of the earportion 290, whereas in FIG. 25, the second material only extends acrossa portion of width of a portion of the ear portion 292.

In alternative embodiments, the recess or opening in the ear portion inwhich the second material is disposed can have any size orconfiguration. The location of the recess or opening for the secondmaterial can vary along the ear portion. As previously discussed, theband portion of an ear warmer can also include a portion of a firstmaterial and a portion of a second material that is different from thefirst material. In an alternative embodiment, the ear portion and/orband portion can include several raised bumps formed on one of itssurfaces. The raised bumps can be located on the first material and/orthe second material if the ear portion includes two different materials.

As illustrated in FIG. 1, the ear warmer 100 includes fabric members 230and 250. The fabric members 230 and 250 are coupled to the frame 110 ofthe ear warmer 100. The fabric members 230 and 250 are configured tosubstantially cover at least a portion of the ear portions 130 and 190of the ear warmer 100. Various configurations of the fabric members aredescribed below.

FIG. 26 shows a side view of a portion of an ear warmer according to anembodiment of the invention. In this embodiment, the frame 310 includesan ear portion 330. A fabric member 350 is fixedly coupled to the earportion 330 of the frame 310. For example, the fabric member 350 can befixedly coupled to the ear portion 330 of the frame 310 by any techniqueor method, including radio frequency (RF) welding, ultrasonic welding,or an adhesive such as glue. For example, the perimeter portion 352 ofthe fabric member 350 can be fixedly coupled to or proximate to theperimeter portion 332 of the ear portion 330 of the frame 310. The term“perimeter portion” is intended herein to include the perimeter or aportion offset from and proximate to the perimeter of a membrane, memberor portion. Following the example shown in FIG. 26, a weld, adhesive orconnector can be located along the actual perimeter of the fabric member350 and a portion of the ear portion 330 of the frame 310 offset fromand proximate to the perimeter of the ear portion 330.

In another embodiment, the fabric member includes binding coupled alongat least a portion of the perimeter of the fabric member. In such anembodiment, the binding can be coupled to the frame using the techniquesidentified above. Alternatively, the fabric member can be coupled to theframe. In this embodiment, the binding provides additional support andcushioning to the user. Additionally, the binding provides a sealbetween the ear warmer and a user's head.

Referring to FIGS. 26A and 26B, which are partial cross-sectional views,an embodiment of an ear portion is illustrated. In this embodiment, theframe 6000, such as an ear portion, includes a fabric member 6050coupled thereto. In one embodiment, fabric member 6050 includes abinding 6100 coupled thereto in any conventional manner. For example,the binding 6100 can be stitched or sewn to the fabric member 6050 byseam 6200. Fabric member 6050 can be coupled to the frame member 6000using any conventional technique, including an adhesive, welding, suchas RF or ultrasonic welding, or the like. In one embodiment, the binding6100 is configured so that a portion of it is disposed adjacent to theinnermost surface of the frame member 6000. The binding 6100 providesadded cushioning, which provides a more comfortable fit. The binding6100 also provides a better seal against a user's head to improvetemperature control by preventing external air from entering any spacebetween the ear portion and the user's head. In an alternativeembodiment, the binding can be replaced by another piece of fabricmaterial, a piece of foam, or any other structure that would assist withthe cushioning and sealing functions above.

FIGS. 27 through 32 show examples of a fabric member that can beremovably coupled to the ear portion of the frame. Although thesefigures show the fabric member being removably coupled to the earportion of frame via press-fit connections, tongue-and-grooveconnections, clip-on connections and slide-and-lock connections, othertypes of the removable connections are also possible. In other words,FIGS. 27 through 32 merely provide examples of removable connections andother types of removable connections are possible.

FIGS. 27 and 28 show a side view and cross-section view along line 28-28in FIG. 27, respectively, of a portion of an ear warmer 400 having apress-fit connection, according to an embodiment of the invention. Earwarmer 400 includes a frame 410 that has an ear portion 430. As shown inFIG. 27, the fabric member 450 can be fixedly coupled to an attachmentmember 460 along a portion of the perimeter of the fabric member 450. Inthis embodiment, the attachment member 460 can be made of, for example,plastic defining an opening 462 along its length and directed inwardly.As shown in FIG. 28, the opening 462 is configured such that theattachment member 460 forms a press fit over a portion of the perimeter432 of the ear portion 430 of the frame 410. This configuration allowsthe fabric member 450 to be removably attached to the ear portion 430 ofthe frame 410. To fit over the outer side of the perimeter 432 of theear portion 430 of the frame 410, the fabric member 450 can be made froman elastic material that is stretched when the fabric member 450 andattachment member 460 are coupled onto the ear portion 430 of the frame410. Alternatively, the fabric member 450 can be larger than the earportion 430 of the frame 410 so that the fabric member 450 can extendover the perimeter 432 of the ear portion 430 of the frame 410 whenbeing configured onto the ear portion 430 of the frame 410.

An alternative embodiment of a portion of an ear warmer 400′ having apress-fit connection, according to the invention is illustrated in FIGS.27A and 27B. Ear warmer 400′ includes a frame 410′ that has an earportion 430′. As illustrated, the fabric member 450′ can be fixedlycoupled to an attachment member 460′ along a portion of the perimeter ofthe fabric member 450′. In this embodiment, the attachment member 460′can be made of, for example, plastic or molded rubber. As illustrated inFIG. 27B, the attachment member 460′ includes a shoulder 463′ thatdefines openings or channels 461′ and 462′ along the length of theattachment member 460′. Opening 461′ is configured such that theattachment member 460′ forms a press fit over a portion of the perimeter432′ of the ear portion 430′ of the frame 410′. This configurationallows the fabric member 450′ to be removably attached to the earportion 430′ of the frame 410′. The shape of the ear portion 430′ andopening 461′ can vary in alternative embodiments.

To fit over the outer side of the perimeter 432′ of the ear portion 430′of the frame 410′, the fabric member 450′ can be made from an elasticmaterial that is stretched when the fabric member 450′ and attachmentmember 460′ are attached to the ear portion 430′ of the frame 410′.Alternatively, the fabric member 450′ can be larger than the ear portion430′ of the frame 410′ so that the fabric member 450′ can extend overthe perimeter 432′ of the ear portion 430′ of the frame 410′ when beingattached to the ear portion 430′ of the frame 410′.

In this embodiment, the fabric member 450′ is coupled to the attachmentmember 460′. As illustrated in FIG. 27B, opening 462′ of the attachmentmember 460′ is configured to receive a portion of the fabric member450′. The fabric member 450′ can be fixedly coupled to the attachmentmember 460′ by conventional coupling technique, including inserting anadhesive, such as glue, into the opening 462′ to couple the fabricmember 450′ thereto. In an alternative embodiment, the fabric member isfused to the attachment member. In this embodiment the fabric member isinserted into the opening of the attachment member. The attachmentmember is then heated such that a portion of the material of theattachment member melts and is absorbed into the fibers of the fabricmember. In one embodiment, the attachment member is made of rubber andmay be heated via any known heating method, including radio frequency(RF) heating. In alterative embodiments, the relative sizes of openings461′ and 462′ can vary.

In alternative embodiment, a portion of an ear warmer 400′ has apress-fit connection, according to the invention is illustrated in FIGS.28A and 28B. Ear warmer 400A includes a frame 410A that has an earportion 430A. As illustrated, the fabric member 450A can be fixedlycoupled to an attachment member 460A along a portion of the perimeter ofthe fabric member 450A. In this embodiment, the attachment member 460Acan be made of, for example, plastic or molded rubber. As illustrated inFIG. 28B, the attachment member 460A includes an opening or channels461A along the length of the attachment member 460A. Opening 461A isconfigured such that the attachment member 460A forms a press fit over aportion of the perimeter 432A of the ear portion 430A of the frame 410A.This configuration allows the fabric member 450A to be removablyattached to the ear portion 430A of the frame 410A. The shape of the earportion 430A and opening 461A can vary in alternative embodiments.

To fit over the outer side of the perimeter 432A of the ear portion 430Aof the frame 410A, the fabric member 450A can be made from an elasticmaterial that is stretched when the fabric member 450A and attachmentmember 460A are attached to the ear portion 430A of the frame 410A.Alternatively, the fabric member 450A can be larger than the ear portion430A of the frame 410A so that the fabric member 450A can extend overthe perimeter 432A of the ear portion 430A of the frame 410A when beingattached to the ear portion 430A of the frame 410A.

As illustrated in FIG. 28B the fabric member 450A is coupled to a sideof the attachment member 460A via any known coupling apparatus and/ormethod, including for example an adhesive. In one embodiment, the fabricmember is fused to the attachment member. In this embodiment, the fabricmember is placed adjacent the attachment member. The attachment memberis then heated such that a portion of the attachment member is meltedand absorbed into the fibers of the fabric member. In one embodiment,the attachment member is made of rubber and may be heated via any knownheating method, including RF heating.

FIGS. 28C through 28G illustrate an ear warmer 400″ having a press-fitconnection, according to an embodiment of the invention. The ear warmer400″ includes a pair of fabric member/attachment member combinations455″ (only one is illustrated) and a frame 410″ that has a first earportion 430″ with a perimeter 432″, a second ear portion with aperimeter (not illustrated), and a band member 415″. Although only onefabric member/attachment member combination 455″ is illustrated anddescribed in detail, it should be understood that both fabricmember/attachment member combinations 455″ can be structurally andfunctionally similar. As shown in FIG. 280, a fabric member 450″ iscoupled (e.g., fixedly coupled) to an attachment member 460″ along atleast a portion of the perimeter of the fabric member 450″. Theattachment member 460″ illustrated in FIG. 28D has a press-fit structurethat defines an opening that is configured to receive the ear portion430″ along at least a portion of the perimeter of the ear portion 430″.Specifically, the opening of the attachment member 460″ is configuredsuch that it forms a complimentary fit over at least a portion of theperimeter 432″ of the ear portion 430″ of the frame 410″. This matingarrangement of the attachment member 460″ and the ear portion 430″allows the fabric member 450″ to be removably attached to the earportion 430″ of the frame 410″. The attachment member 460″ can be madeof any material that allows the attachment member 460″ to be coupled tothe frame, including, for example, rubber, plastic, or metal.Additionally, the fabric member 450″ can be made from an elasticmaterial that is stretched when the fabric member 450″ and attachmentmember 460″ is coupled to the ear portion 430″ of the frame 410″ to fitof the outer side of the perimeter of the ear portion 430″ of the frame410″. Alternatively, the fabric member 450″ can be larger than the earportion 430″ of the frame 410″ so that the fabric member 450″ can extendover the perimeter 432″ of the ear portion 430″ of the frame 410″ whenbeing coupled to the ear portion 430″ of the frame 410″.

As illustrated in FIG. 28C, the ear warmer 400″ includes a connector435″ that is coupled to and extends between the fabric member/attachmentmember combinations 455″. When the fabric member/attachment membercombinations 455″ are coupled to the first ear portion 430″ and thesecond ear portion, respectively, the connector 435″ extends along theband member 415″ of the ear warmer 400″. FIG. 28E is a cross-sectiontaken along 28E-28E of FIG. 28C. As illustrated in FIG. 28E theconnector 435″ includes a protrusion 437″ that is configured to beremovably received by a recess 439″ disposed in the band member 415″.Thus, when the fabric member/attachment member combinations 455″ arecoupled to the first ear portion 430″ and the second ear portion, theconnector 435″ can be secured to the band member 415″.

FIGS. 28F and 28G illustrate alternative embodiments of the connector.As illustrated in FIG. 28F, in one embodiment, the connector 435″includes a opening that is configured to removably receive the bandmember 415″. As illustrated in FIG. 28G, in another embodiment, theconnector 435′″ is configured to be disposed adjacent the band member415′″. In this embodiment, the connector 435″″ may be coupled to theband member 415′″ via a known coupling apparatus and/or method, such asan adhesive.

FIGS. 29 and 30 show a side view and cross-section view along line 30-30in FIG. 29, respectively, of a portion of an ear warmer 500 having apress-fit connection, according to another embodiment of the invention.The ear warmer 500 includes a frame 510 that has an ear portion 530.Similar to that embodiment shown in FIGS. 27 and 28, in FIG. 30, thefabric member 550 can be fixedly coupled to an attachment member 560along a portion of the perimeter of the fabric member 550. In thisembodiment, however, the opening 562 defined by the attachment member560 along its length is directed outwardly. As shown in FIG. 30, theopening 562 has a size such that the attachment member 560 forms a pressfit along a portion of the ear portion 530 of the frame 510. Inparticular, the ear portion 530 of the frame 510 defines an interiorregion defined by a perimeter. The attachment member 560 removablyattaches the fabric member 550 to a portion of this perimeter of theinterior region. The attachment member 560 has sufficient strength andrigidity so that the attachment member 560 is inserted or “popped” intoan opening defined in the ear portion 530.

FIGS. 31 and 32 show a side view and cross-section view along line 32-32in FIG. 31, respectively, of a portion of an ear warmer 600 having atongue-and-groove connection, according to an embodiment of theinvention. In this embodiment, the ear warmer 600 includes a frame 610that has an ear portion 630. As shown in FIG. 32, the fabric member 650can be coupled (e.g., fixedly coupled) to an attachment member 660 alonga portion of the perimeter of the fabric member 650. In this embodiment,the attachment member 660 has a surface with a groove structure formedtherein, and complimentary fits onto or receives the tongue-like portion632 of the ear portion 630 of the frame 610. This mating of theattachment member 660 and the ear portion 630 allows the fabric member650 to be removably attached to the ear portion 630 of the frame 610.The tongue-like portion 632 of the ear portion 630 of the frame 610 canbe monolithically formed with the remaining portions of the ear portion630 of the frame 610. Alternatively, a tongue-like member can be coupled(e.g., fixedly coupled) to the ear portion of the frame by welding or anadhesive. In another alternative embodiment, the tongue-like structurecan be coupled (e.g., fixedly coupled) to the fabric member and thegroove-like structure can be disposed on the ear portion or the frame,for example, either fixedly coupled to or monolithically formed with theear portion of the frame.

FIG. 33 shows a side view of a portion of an ear warmer 700 having aclip-on connection, according to an embodiment of the invention. The earwarmer 700 includes a frame 710 that has an ear portion 730 with aperimeter 732. As shown in FIG. 33, a fabric member 750 can be coupled(e.g., fixedly coupled) to one or more attachment members 760 alongvarious positions of the perimeter of the fabric member 750. Morespecifically, FIG. 33 shows three attachment members 760 although inother embodiments, one, two, four or more than four attachment membersare possible. The various attachment members can be formed integrally orcan be coupled together by different structures. Each of the attachmentmembers 760 shown in FIG. 33 has a clip-like structure that defines anopening 762 along its length and is directed inwardly. These attachmentmembers 760 can be made of any material that allows the attachmentmembers 760 to coupled to the frame, including, for example, plastic ormetal. The opening 762 of each attachment member 760 in configured suchthat it forms a complimentary fit over a portion of the perimeter 732 ofthe ear portion 730 of the frame 710. This mating arrangement of theattachment members 760 and the ear portion 730 allows the fabric member750 to be removably attached to the ear portion 730 of the frame 710.Similar to the embodiment described above in reference to FIGS. 27 and28, to fit of the outer side of the perimeter of the ear portion 730 ofthe frame 710, the fabric member 750 can be made from an elasticmaterial that is stretched when the fabric member 750 and attachmentmembers 760 are coupled onto the ear portion 730 of the frame 710.Alternatively, the fabric member 750 can be larger than the ear portion730 of the frame 710 so that the fabric member 750 can extend over theperimeter 732 of the ear portion 730 of the frame 710 when being coupledonto the ear portion 730 of the frame 710.

FIGS. 34 through 38 show examples of a fabric member removably coupledto the ear portion of the frame by covering substantially an entirety ofthe opening on the inner side of the ear portion of the frame and lessthan an entirety of the opening on the outer side of the ear portion ofthe frame. More specifically, the ear portion of the frame typicallydefines an opening through which sound can pass. This opening has aninterior portion corresponding to the inner side of the ear portion ofthe frame and an exterior portion corresponding to the outer side of theear portion of the frame. As described in more detail in reference toFIGS. 34 through 38, an ear portion of the fabric member can beconfigured such that it covers the interior portion of the openingsubstantially in its entirety and covers the exterior portion of theopening in less than its entirety. Covering the interior portion of theopening “substantially in its entirety” is intended to describeembodiments where the entire interior portion of the opening is coveredexcept for minor exceptions such as, for example, small vents.

FIG. 34 shows a side view of a portion of an ear warmer 800 having afabric member 850, according to an embodiment of the invention. The earwarmer 800 includes a frame 810 that has an ear portion 830. In oneembodiment, the fabric member 850 includes an ear portion with aheat-retaining fabric 852 on the inner side. The ear warmer 800 caninclude an elastic fabric or member 854 on the outer side. In oneembodiment, the elastic fabric 854 is coupled (e.g., fixedly coupled) tothe heat-retaining fabric 852 at three locations. In alternativeembodiments, the elastic or rubber fabric can be coupled to theheat-retaining fabric 852 at any number of locations. In one embodiment,the elastic member 854 can be a clip or snap-on structure that clips orclamps the heat-retaining fabric 852 to the ear portion 830. In analternative embodiment, the elastic member 854 can be a separate piecethat can wrap around the inner side and the outer side of a portion ofthe ear portion 830 and couple the fabric 852 thereto. In anotherembodiment, the heat-retaining fabric 852 and the elastic fabric 854 arecoupled together in a manner other than fixedly coupled, such asremovably coupled.

The fabric member 850 can be removably coupled to the ear portion 830 ofthe frame 810 by stretching the elastic fabric on the outer side of thefabric member 850 so that it can moved over the distal end of the earportion 830 of the frame 810. As shown in FIG. 34, the heat-retainingfabric 852 on the inner side of the fabric member 850 covers theinterior portion of the opening of the ear portion 830 of the frame 810substantially in its entirety while the elastic fabric 854 covers theexterior portion of the opening of the ear portion 830 of the frame 810in less than its entirety. Any combination of coupling techniques can beused to couple the fabric member 850 to the ear portion 830.

FIG. 35 shows a side view of a portion of an ear warmer 900 having afabric member 950, according to another embodiment of the invention. Asshown in FIG. 35, the ear portion of the fabric member 950 has aheat-retaining fabric 952 on the inner side, and an elastic fabricportion 954 and a heat-retaining portion 956 on the outer side. Theelastic fabric can be, for example, a rubber material or aheat-retaining fabric. In this particular embodiment, the outer side ofthe fabric member 950 is coupled (e.g., fixedly coupled) to theheat-retaining fabric 952 on the inner side along a portion of theperimeter. Thus, the fabric member 950 can be removably coupled to theear portion 930 of the frame 910 by stretching the elastic fabric 954 onthe outer side of the fabric member 950 so that it can move over thedistal end 932 of the ear portion 930 of the frame 910. In oneembodiment, the fabric 952 and the heat-retaining portion 956 can beformed integrally.

FIG. 36 shows a side view of a portion of an ear warmer 1000 having afabric member 1050, according to another embodiment of the invention.Fabric member 1050 is coupled in a similar manner as fabric member 850described above. As shown in FIG. 36, the ear portion of the fabricmember 1050 has a heat-retaining fabric 1052 and an elastic fabric 1054.The elastic fabric can be, for example, a rubber material or aheat-retaining fabric. In this particular embodiment, the elastic fabric1054 on the outer side is coupled (e.g., fixedly coupled) to theheat-retaining fabric 1032 on the inner side at two locations. Thefabric member 1050 can be removably coupled to the ear portion 1030 ofthe frame 1010 by stretching the elastic fabric 1054 on the outer sideof the fabric member 1050 so that it can move over the distal end 1032of the ear portion 1030 of the frame 1010.

FIG. 37 shows a side view of a portion of the ear warmer 1100 having afabric member 1150, according to another embodiment of the invention.FIG. 38 shows a perspective assembly view of the portion of the earwarmer 1100 shown in FIG. 37. As shown in FIG. 37, the fabric member1150 (one is shown in FIG. 37 for one ear portion of the frame) has aninner side and an outer side. As shown in FIG. 38, the inner side 1152of the fabric member 1150 includes a coupling portion 1154 embodied as abutton hole. The ear portion 1130 of the frame 1110 includes a couplingportion 1132 embodied as a button and post. The coupling portion 1154 ofthe fabric member 1150 is configured to mate with the coupling portion1132 of the ear portion 1130 of the frame 1110 such that the fabricmember 1150 is removably coupled to the ear portion 1130 of the frame1110. As shown in FIGS. 37 and 38, the coupling portion 1132 of theframe 1110 is disposed on the inner side of the frame.

More specifically, the inner side and outer side of the fabric member1150 form a receptacle 1156 into which the distal end 1134 of the earportion 1130 of the frame 1110 can be removably disposed. This side ofthe ear portion of the fabric member 1150 is referred to herein as thedistal end. The proximate end of the fabric member 1150 is alsoremovably coupled to the ear portion 1130 of the frame 1110, asdiscussed above, by the coupling portion 1154 of the fabric member 1150fitting into the coupling portion 1132 of the ear portion 1130 of theframe 1110. Thus, the overall fabric member 1150 can be coupled to theear portion 1130 of the frame 1110 by coupling the distal end of thefabric member 1150 to the distal end 1134 of the ear portion 1130 of theframe 1110, and then coupling the proximate end of the fabric member1150 to the proximate end of the ear portion 1130 of the frame 1110. Thefabric member 1150 can be removed from the frame 1110 by the reverseprocess.

Although the coupling portion 1132 of the ear portion 1130 of the frame1110 is shown in FIGS. 37 and 38 as protruding from the inner side ofthe frame, in alternative embodiments, the coupling portion of the frameextends from a recess in the inner side of the frame. Thus, the distalend of the coupling portion of the frame corresponds to the remaininginner surface of the ear portion of the frame in that region and ingeneral they form a smooth surface having the recess.

In alternative embodiments, the coupling portion of the ear portion ofthe frame and the coupling portion of the ear portion of the fabricmember can be disposed on any part of the frame, including the outerside of the frame. In such an alternative embodiment, the outer side ofthe ear portion of the frame is substantially covered in its entiretyand the inner side of the ear portion of the frame covered in less thanits entirety.

In an alternative embodiment, the ear portion of the frame and the earportion of the fabric member can be coupled together using anyconventional technique, such as hook-and-loop fasteners, snap-fitconnections, and button-and-hole arrangements having the hole on theframe.

FIGS. 39 and 40 show examples of a fabric member removably coupled tothe frame by covering substantially an entirety of the inner side of theframe and less than an entirety of the opening on the outer side of eachear portion of the frame. More specifically, the examples shown in FIGS.39 and 40 show a fabric member that substantially covers the entirety ofthe inner side of the frame including its ear portions and band portionwhile covering less than the entirety of the outer side of the frame.

FIG. 39 shows a perspective view of a portion of an ear warmer 1200having a fabric member 1250 covering the inner side of the frame 1210,according to an embodiment of the invention. As shown in FIG. 39, thefabric member 1250 has an inner-side portion 1252 and an outer-sideportion 1254. The inner-side portion 1252 of the fabric member 1250corresponds to both ear portions 1230 of the frame 1210 (of which onlyone is shown in FIG. 39) and the band portion 1270 of the frame 1210(only a portion of which is shown in FIG. 39). In this embodiment, theouter-side portion 1254 of the fabric member 1250 can be extended overthe distal end of the ear portions 1230 of the frame 1210. Thus, thedistal end of the ear portions 1230 of the frame 1210 can be retained ina receptacle 1256 formed by the inner-side portion 1252 and theouter-side portion 1254 of the fabric member 1230. The outer-sideportion 1252 of the fabric member 1250 can be made of, for example, anelastic fabric that allows the fabric member 1250 to be stretched overthe distal end of the ear portions 1230 of the frame 1210 to insert andremove the frame 1210 from the fabric member 1250. In alternativeembodiments, the fabric members can be bound, sewn, welded, coupledinside out, or monolithically formed (i.e., unitary construction).

FIG. 40 shows a perspective view a portion of an ear warmer 1300 havinga fabric member 1350 covering the inner side of the frame 1310,according to another embodiment of the invention. As shown in FIG. 40,the fabric member 1350 has only an inner-side portion. The inner-sideportion of the fabric member 1350 corresponds to both ear portions 1330of the frame 1310 (of which only one is shown in FIG. 40) and the bandportion 1370 of the frame 1310 (only a portion of which is shown in FIG.40). In this embodiment, the inner-side portion of the fabric member1350 can be fixedly coupled to the frame 1310 as described above inreference to FIG. 26, or can be removably coupled to the frame, forexample, as described above in reference to FIGS. 31 and 32.

Although not explicitly shown in FIGS. 39 and 40, in alternativeembodiments, the fabric member can cover substantially the entirety ofthe inner side of the frame while being removably coupled to the frameas described above, for example, in reference to FIGS. 27 through 30, 33and 38. In a further alternative embodiment, the fabric member can havea first portion that covers one of the ear portions of the frame and asecond portion that covers the other of the ear portions of the frame.In this embodiment, the first portion of the fabric member can becoupled to the second portion of the fabric member via any type ofcoupling device, such as hook and loop configuration.

FIG. 41 shows a perspective view a portion of an ear warmer 1400 havinga fabric member 1450 and a contact member 1470, according to anotherembodiment of the invention. As shown in FIG. 41, the frame 1410includes a contact member 1470 disposed on the inner side 1432 of theear portion 1430 of the frame 1410. The contact member 1470 isconfigured to provide support and comfort to the user of the ear warmer1400 by contacting the portion of the user's head behind the user'sears. Additionally, the contact member 1470 provides a seal between theambient conditions and the user's ear. In other words, the contactmember fills the gap between the frame 1410 of the ear warmer 1400 andthe user's head. In this embodiment, the contact member 1470 extendsalong a portion of the inner side 1432 of the ear portion 1430. Inalternative embodiments, the contact member extends along substantiallythe entire inner side of the ear portion.

In one embodiment, the fabric member includes a receptacle that receivesthe contact member. In alternative embodiments, the contact member isotherwise coupled to the fabric member, such as via an adhesive. In analternative embodiment, the contact member is coupled to another portionof the ear warmer, such as the band portion of the frame.

In one embodiment, the contact member can be made of a pre-formed foamor rubber material that is covered in fabric. The contact can beslightly deformed and inserted into the opening of the ear portion. Thecontact member is then released and retained via the opening.

In one embodiment, the contact member is a foam material or rubbermaterial that is not covered in fabric. In an alternative embodiment,the contact member is made of a material other than foam. In a furtheralternative embodiment, the contact member is a foam material that iscovered with a material other than fabric.

An ear warmer according to an embodiment of the invention is illustratedin FIG. 49. The ear warmer 2000 includes a frame (not illustrated)disposed within a cavity of a shell 2300. The ear warmer 2000 isdisposable in a collapsed configuration (i.e., when the ear portions aredisposed parallel to and in substantially in the same plane as the bandportion) and an expanded configuration (i.e., when the ear portionsextend away from the band portion). When the ear warmer 2000 is in itsexpanded configuration, the ear warmer 2000 may be placed on a head of auser such that the ear warmer 2000 covers the two ears of the user andextends around a back of the head and/or neck of the user.

An embodiment of a frame according to the invention is illustrated inFIGS. 50 through 59. In this embodiment, the frame 2100 of the earwarmer 2000 includes a band portion 2106, a first ear portion 2102coupled to a first end 2108 of the band portion 2106, and a second earportion 2104 coupled to a second end 2110 of the band portion 2106. Bandportion 2106 includes two or more members that are slidably coupledtogether so that the overall length of the band portion 2106 can beadjusted. In another embodiment, the band portion is a single memberthat does not adjust in length.

Specifically, in this embodiment, the first ear portion 2102 includes afirst end portion 2112 and a second end portion 2114. The first endportion 2112 is coupled to the band portion 2106. The second end portion2114 of the first ear portion 2102 is disposed opposite the first endportion 2112 of the first ear portion 2102 and distal from the bandportion 2106 when the frame is in its expanded configuration. Similarly,the second ear portion 2104 includes a first end portion 2116 and asecond end portion 2118. The first end portion 2116 is coupled to theband portion 2106. The second end portion 2118 of the second ear portion2104 is disposed opposite the first end portion 2116 of the second earportion 2104.

In one embodiment, the first ear portion 2102 and the second ear portion2104 are movably coupled to the band portion 2106. Connectors 2120 and2122 rotatably couple the first ends 2112 and 2116 of the ear portions2102 and 2104 to the ends 2108 and 2110 of the band portion 2106,respectively. Connectors 2120 and 2122 are inserted through openings2127 (only one is illustrated) formed in the ear portions 2102 and 2104and through openings 2164 (only one is illustrated) formed in the bandportion 2106. Thus, the ear portions 2102 and 2104 are coupled to theband portion 2106 such that the ear portions 2102 and 2104 may rotate orpivot about connectors 2120 and 2122 with respect to the band endportions 2108 and 2110, respectively. In one embodiment, the connectors2120 and 2122 are rivets. In alternative embodiments, the connectors areother types of coupling mechanisms, such as brads or screws. In anotherembodiment, a connecting structure, such as a projection, is coupled toeach ear portion and subsequently inserted through the opening in theband portion. In alternative embodiments, the first ear portion and thesecond ear portion are rotatably and/or slidably coupled to the bandportion.

When the ear warmer is placed on a user's head, the ear portions andband portion collectively provide a clamping force which keeps the earwarmer on the user's head. The band portion and the ear portions acttogether as a biased clamp. If an ear portion is rigid or substantiallyrigid, the clamping pressure or force applied on the user's head by theear portion is localized proximate to the uppermost and/or lowermostpoints on the ear portion. If the clamping pressure or force is appliedover a small area, the pressure may become uncomfortable for the user.

Different embodiments of the ear warmer apply different amounts ofpressure or force to a user's head. Additionally, different embodimentsof the ear warmer apply the pressure or force to different locations onthe user's head. Specifically, the pressure and pressure location can beadjusted between different embodiments of the ear warmer by modifyingthe band portion and/or the ear portions. In other words, the amount ofpressure applied and the pressure location for one embodiment of an earwarmer is different than the amount of pressure applied and the pressurelocation for an ear warmer of another embodiment. For example, theapplied pressure for one embodiment is less than or greater than theapplied pressure for another embodiment having lesser or greater,respectively, the thickness and/or width of the band portion, butsubstantially equal thickness and width of the ear portions.Alternatively, the applied pressure for one embodiment having earportions of a certain thickness is less than the applied pressure foranother embodiment having ear portions of a lesser thickness.Additionally, one embodiment of an ear portion has a certain thicknessand is less flexible than an ear portion of another embodiment having athickness greater than the thickness of the ear portion of the oneembodiment. Additionally, one embodiment of an ear portion has a certainthickness and applies pressure or force to a user's head over a smallerarea than an embodiment of an ear portion having a lesser thickness thanthe ear portion of the one embodiment. Embodiments of ear portions whichapply pressure to a large area of a user's head is more comfortable thanembodiments of ear portions that apply pressure to a small area of theuser's head.

The pressure that is applied by an ear warmer of a particular embodimentto a user's head over a particular area is a function of the thicknessof the material and the surface area dimension over that area of the earportion. For example, if one embodiment of the ear warmer ismanufactured with an ear portion that is thinner than an ear portion ofa further embodiment, then the clamping pressure produced by the earwarmer of the one embodiment will be less than the clamping pressureproduced by the ear warmer of the further embodiment. Additionally, ifone embodiment of the ear warmer is manufactured with a smaller overallsize then the overall size of the ear warmer of a further embodiment,then the clamping pressure produced by the ear warmer of the oneembodiment will be less than the clamping pressure produced by the earwarmer of the further embodiment. The ear warmer, however, should applysufficient pressure to the user's head retain the ear warmer on theuser.

Additionally, the clamping pressure and the location of the pressure candiffer among different embodiments of an ear warmer by providing the earportion with a curved configuration. Specifically, the configuration ofthe ear portion affects where the ear portion flexes when the ear warmeris placed on a user's head. For example, if one embodiment of the earwarmer is manufactured with an ear portion that is substantially flat(for example, having only a small curved portion), then, when forces areapplied to the ear warmer, the ear portion will bend and flex at itsweakest point or where it curves. Alternatively, if another embodimentof the ear warmer is manufactured with an ear portion that has a curvedconfiguration (for example, having a substantial amount of the earportion being curved), then, when forces are applied to the ear warmer,the ear portion will bend and flex over a substantial portion of the earportion. As the flexible area or curved portion of the ear portionincreases, the bending forces are distributed over a larger portion ofthe ear portion. A larger distribution of bending forces reduces thepotential for a stress failure on the ear portion because the bendingforces are spread out over a larger portion of the ear portion. Anincrease in the range of curvature and the flexibility of the earportion also results in a more uniform distribution of the clampingforce on the user's head. Additionally, as the curved portion of the earportion is increased (between different embodiments of the ear warmer),the pressure applied by the ear warmer to the head of a user at anyonelocation is decreased. In one embodiment of an ear warmer, the earportion has a distal end disposed inwardly of its coupling to the bandportion in its deployed configuration. The term “inwardly” is usedherein to mean towards a user's head when the ear warmer is worn by auser or towards a point disposed such that the inner side of the earportion is disposed between the point and the outer side of ear portion.

The increase in curvature of the ear portions also results in a smallercollapsed configuration of the ear warmer when the ear portions aremoved to their collapsed positions relative to the band portion. Whenthe ear warmer is collapsed, the distal end of each ear portion isdisposed proximate to or extends slightly beyond the opposite end of theband portion than that to which the particular ear portion is coupled.The overall result is a lower and narrower profile of the ear warmer inits collapsed configuration.

In several embodiments of an ear warmer according to this invention, theamount of the ear portion that is curved is greater than other known earwarmers. Additionally, the profile or distance that the ear warmerextends from the user's head is also modified to achieve a different(such as a more comfortable) fit on the user's head. It can beappreciated that either or both of the curvature and the profile of aparticular embodiment of an ear warmer can be different than thecurvature and the profile of another embodiment of an ear warmer.

Returning to the embodiment of the ear warmer illustrated in FIGS. 50through 59. The first ear portion 2102 of the frame 2100 and the secondear portion 2104 of the frame 2100 are functionally and structurallysimilar. Therefore, only the first ear portion 2102 is discussed indetail.

An embodiment of an ear portion is illustrated in FIGS. 51 through 57.In this embodiment, the first ear portion 2102 includes a couplingportion 2126, a first projecting portion 2128, a second projectingportion 2130, and an extension member or portion 2132. The first earportion 2102 includes an opening 2124 that is defined by the firstprojecting portion 2128, the second projecting portion 2130 and theextension portion 2132. The first ear portion 2102 is curved such thatthe second end portion 2114 extends downwardly farther than the firstend portion 2112 as illustrated in FIG. 57.

In one embodiment, the first projecting portion and the secondprojecting portion are structurally and functionally similar. In anotherembodiment, the first projecting portion and the second projectingportion are not structurally and functionally similar. For example, oneof the projecting portions can be thicker than the other projectingportion to achieve a different spreading and intensity of pressure on auser's head such as the upper or lower side of the ear portion when wornby a user. Also, the length of one of the projecting portions can bedifferent than the other projecting portion to achieve a differentpositioning of the ear portion on the user's head. Moreover, one or bothof the projecting portions can be substantially linear, partially orsubstantially curved, or have any other shape or configuration.

In one embodiment of an ear portion, the first and second projectingportions extend from the coupling portion symmetrically about an axisalong the coupling portion. For example, the first and second projectingportions can be substantially linear and can extend from the couplingportion to form an acute angle. Alternatively, the first and secondprojecting portions can be curved or have curved portions. In anotherembodiment, the first and second projecting portions do not extend fromthe coupling portion symmetrically.

In one embodiment, the first and second projecting portions and theextension member collectively have a frusto-conical configuration. Inalternative embodiments, these parts collectively may have a differentshape or configuration. Also, each of these parts may have an ovalcross-section that is vertically upright or inclined, a circularcross-section, or a square or rectangular shaped cross-section.Different cross-sectional configurations of the projecting portions andthe extension member result in different amounts and locations ofpressure on the user's head.

The coupling portion 2126 is disposed adjacent to and is coupled to theband portion 2106 of the frame 2100. In this embodiment, the couplingportion 2126 of the first ear portion 2102 includes an mounting opening2127 that is configured to receive a connector 2120 to couple the firstear portion 2102 to the band portion 2106.

The first projecting portion 2128 and the second projecting portion 2130are each coupled to and extend from the coupling portion 2126. Theextension portion 2132 extends between the ends of the first projectingportion 2128 and the second projecting portion 2130.

In this embodiment, the first projecting portion 2128 is coupled to theextension member 2132 proximate to the lowermost point 2129 of the firstear portion 2102 (see FIG. 54). The lowermost point 2129 of the firstear portion 2102 is the lowermost point of the first ear portion 2102when the ear warmer 2000 is disposed on a head of a user. Similarly, thesecond projecting portion 2130 is coupled to the extension member 2132proximate to the uppermost point 2131 of the first ear portion 2102. Theuppermost point 2131 of the first ear portion 2102 is the uppermostpoint of the first ear portion 2102 when the ear warmer 2000 is disposedon a head of a user. In an alternative embodiment, the first projectingportion is coupled to the extension member at a location different thanthe lowermost point. In another embodiment, the second projectingportion is coupled to the extension member at a location different thanthe uppermost point of the first ear portion.

Although points on the first ear portion 2102 have been identified asuppermost and lowermost it should be understood that there may be, forexample, several uppermost points of the first ear portion. In such acase, the “uppermost point” includes the several points. Similarly,there may be several lowermost points of the first ear portion. In sucha case, the “lowermost point” includes the several points. It should beunderstood that the uppermost point and the lowermost point are fixedpoints on the ear portion and do not change according to the orientationof the frame at any given time.

In one embodiment, each of the first projecting portion 2128 and thesecond projecting portion 2130 has a substantially linear portion 2128 aand 2130 a (adjacent the coupling portion 2126) and a slightly curvedportion 2128 b and 2130 b (adjacent the extension member 2132) whenviewed from the side of the first ear portion (see FIGS. 54 and 55). Inalternative embodiments, the first projecting portion and the secondprojecting portion are linear and do not include curved portions whenviewed from the side of the first ear portion.

In one embodiment, the coupling portion 2126, the first projectingportion 2128, the second projecting portion 2130, and the extensionmember 2132 are unitarily (or monolithically) formed. In other words,the portions 2126, 2128, and 2130 and the extension member 2132 of thefirst ear portion 2102 are made of a singe piece of material.

The first ear portion 2102, including the portions 2126, 2128, and 2130and the extension member 2132, can be manufactured by injection molding.Injection molding involves the introduction of the molten material, suchas a plastic, into a mold. The molten material is inserted through anopening in the mold and fills the cavities in the mold. The location onthe molded article that corresponds to where the molding material isinserted into the mold can be referred to as the molding gate. Themolding gate represents a location or portion of the molded article thatis more likely to fail or break due to stress than other locations orportions of the molded article. If the molding gate is located along anyof the coupling portion 2126, the first projecting portion 2128, thesecond projecting portion 2130 and the extension member 2132, the earportion may break at or near the molding gate during ordinary use of theear warmer. Accordingly, by locating the molding gate on part of the earportion that is offset from any of the portions 2126, 2128 and 2130 andextension member 2132, the potential for a failure or fracture duringordinary use of the ear warmer may be reduced.

In the illustrated embodiment, the ear portion includes a projection2137 that extends into the opening 2124 defined by the ear portion 2102.The molding gate 2138 is disposed or located on the projection 2137 asillustrated in FIGS. 51 and 54. In alternative embodiments, the moldinggate can be located on a projection or other structure that is coupledto the ear portion at any location. For example, the projection thatincludes the molding gate can be coupled to the coupling portion, thefirst or second projecting portions, or the extension member or portion.

In alternative embodiments, the portions and the extension member of thefirst ear portion are several different individual pieces and arefixedly coupled to one another via a conventional coupling mechanismsuch as an adhesive, screws, or rivets.

As illustrated in FIGS. 56 and 57, the first ear portion 2102 has alength L that extends from the first end portion 2112 of the first earportion 2102 to the second end portion 2114 of the first ear portion2102. As illustrated in FIGS. 52 and 53, the first ear portion 2102 alsohas a longitudinal plane P that extends from the first end portion 2112to the second end portion 2114 along the length L. The first ear portion2102 has an outer side 2142, an inner side 2140 (the side proximate theuser's head and disposed between outer side 2142 and a user when the earwarmer is worn by the user), an upper side 2144 (see FIGS. 52 and 54—theside that faces up when the ear warmer is worn by a user), and a lowerside 2146 (see FIGS. 52 and 54—the side opposite the upper side 2144 andthat faces down when the ear warmer is worn by a user). The first earportion 2102 also has an innermost surface or edge 2148. The innermostsurface 2148 of the first ear portion 2102 is the portion or surface ofthe inner side 2140 of the first ear portion 2102 that is disposedclosest to a user's head when the ear warmer is worn by the user. In oneembodiment, the innermost surface 2148 extends along a perimeter of thefirst ear portion 2102. For example, in one embodiment, the innermostsurface 2148 extends along an outer perimeter of the first ear portion.In an alternative embodiment, the innermost surface 2148 extends alongan inner perimeter of the first ear portion.

In one embodiment, the first ear portion 2102 has a thickness dimensionthat is defined by the distance at a particular location on the firstear portion 2102 between the inner side 2140 and the outer side 2142. Asillustrated in FIG. 56, the thickness dimension can vary along thelength of the first ear portion 2102. In particular, the thicknessdimension of the first ear portion varies along the first and secondprojecting portions 2128 and 2130 and the extension member 2132. Arepresentative thickness dimension of the coupling portion 2126 isdesignated as T_(C) in FIG. 56. Similarly, representative thicknessdimensions of the projecting portions and the extension member 2132 aredesignated as T_(P) and T_(E), respectively. In this embodiment, T_(C)is substantially the same as T_(P), which is greater than T_(E). Thus,the coupling portion 2126 is the thickest portion of the ear portion2102 and the ear portion 2102 is tapered from the projecting portions2126 and 2128 to the distal end 2114 of the ear portion 2102. Thetapered configuration of the ear portion 2102 allows the ear portion2102 to flex differently over various locations on the ear portion whenthe ear warmer 2000 is disposed on a user's head. In other words, thereduced thickness of the ear portion enables the ear portion to flattenout against the user's head when the ear warmer is disposed on a user'shead. Thus, the forces that are applied by the ear warmer 2000 on theuser's head is spread over a large portion of the ear portion 2102.Therefore, the force applied by the ear warmer 2000 on the user's headat anyone point of the ear portion 2102 is less than would be otherwisebe the case if the ear portion did not have a tapered configuration.

In an alternative embodiment, the ear portion can include a steppedtaper as opposed to a gradual taper. In another embodiment, the earportion can include a reverse taper with the extension member having agreater thickness than the coupling portion. In another embodiment, thethickness can vary. In another embodiment, the thickness of the couplingportion is greater than the thickness of the projecting portions, whichin turn is greater than the thickness of the extension member.

As previously discussed, when a user wears the ear warmer 2000 on theuser's head, the ear portions 2102 and 2104 are disposed proximate tothe user's head. The ear warmer 2000 may have one or more layers offabric coupled thereto. The shape of the ear portions and the bandportion direct the ear portions inwardly to provide a clamping force onthe user's head.

A substantial section of each ear portion (such as 50% or more of thelength of the ear portion) contacts the user's head when the ear warmeris disposed on a user's head. In one embodiment, more than 50% of thelength of the ear portion contacts the user's head when the ear warmeris disposed on the user's head. In particular, as illustrated in FIG.54, the part of the first ear portion 2102 that extends continuouslyfrom approximately point 2196 on second projecting portion 2130, aroundextension member 2132, and to approximately point 2198 on firstprojecting portion 2128 is disposed proximate to the user's head whenthe user wears the ear warmer. This part of the first ear portion 2102is a substantial portion of the extent or perimeter of the first earportion 2102. Accordingly, pressure is applied to the user's head alongthis part of the first ear portion 2102 from point 2196 to point 2198.

The following data is only representative of several examples of an earportion and is not intended to be limited in any respect. In oneembodiment, the thicknesses T_(C) and T_(P) are approximately 0.057inches (1.45 millimeters) and thickness T_(E) at the distal end isapproximately 0.035 inches (0.89 millimeters). In another embodiment,the thicknesses T_(C) and T_(P) are approximately 0.054 inches (1.37millimeters) and thickness T_(E) is approximately 0.033 inches (0.84millimeters). In one instance, the change from a thickness of 0.057inches (1.45 millimeters) to a thickness of 0.054 inches (1.37millimeters) for T_(C) and T_(P) results in the distal or second end ofthe ear portion applying a one ounce less of force to the user's head.

In some embodiments of an ear warmer, the range of force applied by thedistal end of the ear portion to the user's head is approximately six tosixteen ounces. In some embodiments, the pressure applied by the distalor second end of the ear portion to the head is in the range of nine totwelve ounces. The amount of pressure applied by the distal end portionof the ear portion is measured with the band portion disposed at amid-length (when the band portion is disposed at the middle of its rangeof motion).

As illustrated in FIG. 56, the first ear portion 2102 includes severaldifferent curved portions. Specifically, in the illustrated embodiment,the first end portion 2112 of the first ear portion 2102 issubstantially linear. Additionally, a middle portion 2150 of the firstear portion 2102, which is disposed between the first end portion 2112of the first ear portion 2102 and the second end portion 2114 of thefirst ear portion 2102, and the second end portion 2114 of the first earportion 2102 have a curved shape or configuration, as illustrated inFIGS. 56 and 57, when the ear warmer is in an unbiased condition. Theterm “unbiased” is used herein to mean without the application of anexternal force or pressure. In other words, the ear warmer is in itsunbiased condition when it is at rest and does not have a user appliedforce, such as by a user's head or other body part, applied to it. Themiddle portion 2150 and the second end portion 2114 curve toward or areconcave with respect to a point G that is disposed at a location apartfrom the first ear portion 2102 such that the inner side 2140 of thefirst ear portion 2102 is disposed between point G and the outer side2142 of the first ear portion 2102. In other words, the first earportion 2102 is curved such the second end portion 2114 of the first earportion 2102 is configured to be disposed closer to a user's head, or toplace more pressure on the user's head, than the first end portion 2112of the first ear portion 2102. This enables the pressure applied by thesecond or distal end of the first ear portion to the user's head to beless. This configuration also directs the frame pressure toward thedistal end 2114 of the ear portion.

In one embodiment, a substantial amount (such as 50% or more) of thefirst ear portion 2102 along its length L, including part or all of theprojecting portions and all of the extension member, is curved inwardlytoward the inner side 2140 of the first ear portion 2102. In otherembodiments, less than a substantial amount of the length L of the firstear portion 2102 is curved. As illustrated by the dashed line in FIG.57, the ear portion 2102, in one example, has a length L_(E) when theear portion 2102 is flexed such that the ear warmer 2000 may be disposedon a user's head.

In one embodiment, the different parts of the first ear portion 2102have different radii of curvature. In other words, one part of the firstear portion 2102 has a first radius of curvature and another part of thefirst ear portion 2102 has a second radius of curvature different fromthe first radius of curvature. Specifically, a first part or section ofthe curved portion, corresponding in part to the first and secondprojecting portions, is curved about a first axis Q and has a radius ofcurvature. The first axis Q is disposed substantially orthogonal to thelongitudinal plane P of the ear portion. The second part or section ofthe curved portion, corresponding to the extension member, is curvedabout a second axis R and has a radius of curvature different from thatof the first part of the curved portion. The second axis R is disposedsubstantially orthogonal to the longitudinal plane P of the ear portion.In one embodiment, the first axis is spaced apart from the second axis.In this embodiment, the middle portion 2150 of the first ear portion2102 has a first radius of curvature. Similarly, the second end portion2114 of the first ear portion 2102 has a second radius of curvature,which is greater than the first radius of curvature. In an alternativeembodiment, the curved portion of the first ear portion has a constantradius of curvature. In another embodiment, the first radius ofcurvature is greater than the second radius of curvature.

In one embodiment, the sum of the length of the first curved portion ofthe ear portion and the length of the second curved portion of the earportion is half of the length of the ear portion. In another embodiment,the sum of the length of the first curved portion and the length of thesecond curved portion of the ear portion is two-thirds the length of theear portion. In a further embodiment, the sum of the length of the firstcurved portion of the ear portion and the second curved portion of theear portion is four-fifths the length of the ear portion. In a furtherembodiment, the sum of the length of the first curved portion of the earportion and the length of the second curved portion of the ear portionis equal to the length of the ear portion.

In the illustrated embodiment, the extension member 2132 includes aninnermost surface or edge 2149 which is a portion of the innermostsurface 2148 of the first ear portion 2102. The innermost surface 2149of the extension member 2132 is curved toward the inner side 2140 of thefirst ear portion 2102 and is non-planar. In other words, the innermostsurface 2149 of the extension member 2132 has a curved configuration andis not disposed in anyone plane. In an alternative embodiment, only aportion of the innermost surface of the extension member is curved.

In one embodiment, a substantial amount (such as 50% or more) of thefirst ear portion 2102 along its length L of the first ear portion 2102is configured to flex or bend when the ear warmer 2000 is disposed on ahead of a user. In particular, part or all of the projecting portionsand the extension member have tapered configurations and curved profilesor configurations that allow the ear portion to flex or bend. The curvedconfiguration of the ear portion 2102 results in the flexing of the earportion along the length of the ear portion, thereby distributing theflexing forces along a substantial portion of the length of the earportion. When the ear warmer 2000 is disposed on the user's head, aclamping force is applied to the user's head and the reactionary forceon the ear portion 2102 is shown in FIG. 56. The curvature of the earportion 2102 alone or in combination with other features of the earportion 2102 allow the ear portion to flex along a substantial portionof its length (such as 50% or more) when the ear warmer 2000 is disposedon a head of a user. The flexing is also enhanced by the reducedthickness of the ear portion. Thus, as pressure is applied to the earportion, the ear portion flattens out so that an increased amount of theear portion is proximate to and applying pressure to the user's head andmore pressure is applied to the end 2114. In particular, the extensionmember can follow the contour of the face and bone structure of theuser. The first ear portion 2102 in its flexed configuration isillustrated in FIG. 57 in dashed lines.

Thus, a substantial amount of the length L of the first ear portion 2102conforms to and applies pressure to a side of a head of a user when theear warmer 2000 is disposed on the user's head. In other embodiments,the extent of the ear portion that is configured to flex when the earwarmer is disposed on a head of a user can vary. In other words, theextent of the ear portion of one embodiment that is configured to flexwhen the ear warmer is disposed on a head of a user may be differentthan the extent of the ear portion of another embodiment that isconfigured to flex when the ear warmer is disposed on a head of a userin a different embodiment. For example, in one embodiment, only theextension member bends or flexes. In alternative embodiments, the otherparts of the ear portion can bend or flex.

As discussed above, the extension member 2132 is configured to flex orbend when the ear warmer 2000 is disposed on a head of a user. Theextension member 2132 is configured to conform to the shape of a head ofa user to comfortably secure the ear warmer 2000 to the head of theuser. In one embodiment, the projecting portions and the extensionmember collectively have a frusto-conical configuration. The extensionmember and the projecting portions flatten out as the ear portioncontacts the user's head. In an alternative embodiment, only a portionof the extension member is configured to flex or bend when the earwarmer is disposed on a head of a user. In a further embodiment, theextension member is not configured to flex or bend when the ear warmeris disposed on a head of a user. Rather, another portion of the framesuch as the band portion is configured to flex.

Referring to FIGS. 57A and 57B, an embodiment of an ear portion for aframe of an ear warmer is illustrated. The ear portion 2102′ defines anopening 2124′ and includes a coupling projection 2126′, a first supportprojection or projecting portion 2128′, a second support projection orprojecting portion 2130′, and an extension member or portion 2132′. Thefirst support projection 2128′ and the second support projection 2130′are each coupled to and extend from the coupling projection 2126′. Theextension member 2132′ is coupled to the first support projection 2128′and to the second support projection 2130′. In one embodiment, theextension member 2132′ can have a substantially circular cross-section.In another embodiment, the extension member 2132′ can have any type ofcross-section, such as rectangular or triangular.

The ear portion 2102′ includes a length L′ that extends from a first endportion 2112′ of the ear portion 2102′ to a second end portion 2114′ ofthe ear portion 2102′. The ear portion 2102′ has an outer side 2142′ andan inner side 2140′ (the side disposed between outer side 2142′ and auser when the ear warmer is worn by the user). The ear portion 2102′also has an innermost surface 2148′. The innermost surface 2148′ of theear portion 2102′ is the portion or surface of the inner side 2140′ ofthe ear portion 2102′ that forms the inner edge of the ear portion 2102′and is disposed closest to a user's head when the ear warmer is worn bythe user.

Referring to FIG. 57B, the ear portion 2102′ includes several differentcurved portions. Specifically, the first end portion 2112′ of the firstear portion 2102′ is substantially linear. Additionally, in theillustrated embodiment, a middle portion 2150′ of the ear portion 2102′,which is disposed between the first end portion 2112′ of the ear portion2102′ and the second end portion 2114′ of the first ear portion 2102′,and the second end portion 2114′ of the first ear portion 2102′, have acurved shape. The middle portion 2150′ and the second end portion 2114′curve toward a point J that is disposed at a location apart from thefirst ear portion 2102′ such that the inner side 2140′ of the first earportion 2102′ is disposed between point J and the outer side 2142′ ofthe first ear portion 2102′. In other words, the ear portion 2102′ iscurved such that the second end portion 2114′ of the first ear portion2102′ is configured to be disposed closer to a user's head, or to placemore pressure on the user's head, than the first end portion 2112′ ofthe ear portion 2102′.

In this embodiment, a substantial amount of the length L′ of the earportion 2102′ is curved toward the inner side 2140′ of the ear portion2102′. In other embodiments, less than a substantial amount of thelength L′ of the ear portion 2102′ is curved.

In this embodiment, the curved portions of the first ear portion 2102′do not form a continuous curve. Specifically, a first part of the curvedportion is curved about a first point and the second part of the curvedportion is curved about a second point. The first part or section of thecurved portion has multiple radii of curvature and the second part orsection of the curved portion has its own radius of curvature, which isdifferent than any of the radii of curvature of the first part orsection.

The extension member 2132′ includes an innermost surface 2149′ which isa portion of the innermost surface 2148′ of the ear portion 2102′. Theinnermost surface 2149′ of the extension member 2132′ is curved towardthe inner side 2140′ of the first ear portion 2102′ and is non-planar.In other words, the innermost surface 2149′ of the extension member2132′ is not disposed in anyone plane. In this embodiment, the extensionmember includes a rear portion 2141′ that is substantially linear andthat extends beyond the coupling point with portion 2130′. Inalternative embodiments, the entire extension member is curved. In otherwords, the extension member does not include a linear portion. In analternative embodiment, the extension member 2132′ does not include rearportions 2141′ that extend beyond portions 2128′ and 2130′.

A substantial amount (such as 50% or more) of the length L′ of theextension member 2132′ is configured to flex or bend when the ear warmeris disposed on a head of a user. Thus, a substantial amount of thelength L′ of the extension member 2132′ is configured to conform to andapply pressure to a side of a head of a user when the ear warmer isdisposed on a user's head.

The innermost surface 2149′ of the extension member 2132′ is configuredto flex or bend when the ear warmer is disposed on a head of a user. Inother words, the innermost surface 2149′ of the extension member 2132′is configured to conform to the shape of a head of a user to comfortablysecure the ear warmer to the head of the user.

Turning to the band portion of the frame, the band portion is configuredto extend around a back of a head of a user when the ear warmer 2000 isdisposed on the user. Several examples of such a band portions aredisclosed in U.S. patent application Ser. No. 10/056,093, filed on Jan.28, 2002, the disclosure of which is incorporated herein by reference.

FIGS. 58 and 59 illustrate a band portion 2106 of the frame 2100according to an embodiment of the invention. The band portion 2106 has afirst end 2152 and a second end 2154 opposite the first end 2152 of theband portion 2106. The band portion 2106 has a length, which extendsfrom the first end 2152 of the band portion 2106 to the second end 2154of the band portion 2106. The length of the band portion 2106 may beadjusted by a user to change the length of the band portion 2106 betweenthe first end 2152 of the band portion 2106 and the second end 2154 ofthe band portion 2106. In other words, the length of the band portion2106 may be adjusted to change the length of the band portion 2106between the first ear portion 2102 and the second ear portion 2104.Thus, the size of the ear warmer 2000 may be changed. As the length ofthe band portion 2106 is changed, the pressure applied by the earportions varies because the ear portions are disposed at differentangles.

As illustrated, the band portion 2106 has a first member 2156 and asecond member 2158, which are slidably coupled to one another. The firstmember 2156 of the band portion 2106 has a curved configuration andincludes a first end 2160 and a second end 2162. The first member 2156has a coupler 2168 disposed proximate the second end 2162 of the firstmember 2156. The coupler 2168 defines an opening 2170 (see FIG. 59) thatis configured to receive the second member 2158 of the band portion2106, and thereby, slidably couple the second member 2158 of the bandportion 2106 to the first member 2156 of the band portion 2106.

Similar to the first member 2156 of the band portion 2106, the secondmember 2158 of the band portion 2106 has a curved configuration andincludes a first end 2172 and a second end 2174. The second member 2158includes a coupler 2176 disposed proximate the second end 2174 of thesecond member 2158. The coupler 2176 defines an opening (notillustrated) that is configured to receive the first member 2156 of theband portion 2106, and thereby, slidably couple the first member 2156 ofthe band portion 2106 to the second member 2158 of the band portion2106.

In an alternative embodiment, either the first member of the bandportion slidably receives the second member of the band portion or thesecond member slidably receives the first member of the band portion.

In the illustrated embodiment, the couplers 2168 and 2176 are formedunitarily or monolithically with the first member 2156 of the bandportion 2106 and the second member 2158 of the band portion 2106,respectively. In an alternative embodiment, the couplers are coupled tothe members of the band portion via brads, screws, an adhesive, or anyother known coupling mechanism.

The first member 2156 of the band portion 2106 includes an inner side2180 and an outer side 2182 opposite the inner side 2180. The inner side2180 of the first member 2156 of the band portion 2106 is disposedbetween a head of a user and the outer side 2182 when the ear warmer isdisposed on the head of the user. The outer side 2182 of the firstmember 2156 of the band portion 2106 is the side of the band portionthat is disposed away from a head of a user when the ear warmer isplaced on the head of the user. In one embodiment, the outer side 2182of the first member 2156 includes an alignment mechanism, such asseveral ridges or several spaced-apart recesses 2184 formed therein. Therecesses 2184 are shallow recesses formed in the first member 2156. Theedges 2185 of the recesses 2184 and the recesses 2184 are configured tobe engaged by an edge of the coupler 2176 of the second member 2158 thatdefines the opening of the coupler 2176. The recesses 2184 allow theband portion 2106 to be temporarily retained in several differentlengths and configurations. The coupler 2176 engages the edges 2185 andthe recesses 2184 of the second member 2158 and provides some resistanceto the movement of the first member 2156 of the band portion 2106relative to the second member 2158. Thus, a user may move or slide thefirst member 2156 with respect to the second member 2158 to place theband portion 2106 of the ear warmer 2000 in anyone of the severaldifferent discrete locations. When the ear warmer is put on a user'shead, the first ends 2152 and 2160 are spread apart and the frictionbetween the couplers and the band members increases, thereby resistingmovement of the members of the band portion relative to each other.

In an alternative embodiment, another surface, such as the innersurface, an upper surface, or a lower surface, of the first member ofthe band portion includes recesses. In another alternative embodiment,the second member of the band portion includes recesses that areconfigured to be engaged by the coupler of the first member of the bandportion. In a further alternative embodiment, each of the first memberand the second member of the band portion includes recesses that areconfigured to be engaged by the coupler of the second member and thefirst member, respectively. In another embodiment, the band portionsinclude an alignment mechanism, such as raised areas or ridges.

Openings are disposed proximate the first end of each of the firstmember and the second member to couple the ear portions 2102 and 2104 tothe band portion 2106. For example, as illustrated in FIG. 59, anopening 2164 is disposed proximate the first end 2160 of the firstmember 2156. The openings 2164 are configured to receive the connectors2120 and 2122 to pivotally couple the ear portions 2102 and 2104 to theends 2172 and 2160 of the members 2158 and 2156, respectively. The earportions 2102 and 2104 can be pivoted from a collapsed configuration toan expanded configuration.

As illustrated in FIG. 58, each band member includes an aligningcomponent, such as a groove or a projection. A projection 2186 isdisposed on the inner side 2180 of the first member 2156 of the bandportion 2106. Similarly, a projection 2188 is disposed on an inner side2190 of the second member 2158 of the band portion 2106. The projection2186 is configured to be received by slot 2192, which is defined byridges 2191 (as illustrated in FIGS. 51, 52, and 54) disposed on theouter side of the ear portion 2102 when the ear warmer 2000 is in itsexpanded configuration. Similarly, projection 2188 is configured to bereceived by a slot that is defined by ridges disposed on the outer sideof the ear portion 2104 when the ear warmer 2000 is in its expandedconfiguration. The interaction between the projections 2186 and 2188 andthe slots 2192 removably retain the ear warmer in its expandedconfiguration and provide tactile and/or audible feedback to the userwhen the ear warmer 2000 is moved into or out of its expandedconfiguration.

A user may apply force to the ear portions 2102 and 2104 to pivot theear portions 2102 and 2104 to convert the ear warmer 2000 from itscollapsed configuration to its expanded configuration. When the earportions 2102 and 2104 are moved into their expanded positions, theprojections 2186 and 2188 of the band members 2156 and 2158 engage theslots 2192 of the ear portions 2102 and 2104, respectively. Similarly,the user may apply force to the ear portions 2102 and 2104 to pivot theear portions 2102 and 2104 to convert the ear warmer 2000 from itsexpanded configuration to its collapsed configuration, and therebyremove the projections 2186 and 2188 of the band members 2156 and 2158from the slots 2192 of the ear portions 2102 and 2104, respectively. Inalterative embodiments, each of the slots can be formed by anotherconfiguration such as a “U” shaped projection or an oval projection. Inalternative embodiments, ridges and projections can be disposed on theband members and the projections are disposed on the ear portions.

Turning to the fabric member or shell of an ear warmer incorporating aframe such as that illustrated in FIG. 50, the shell includes a cavityconfigured to receive the frame of the ear warmer. Several examples ofsuch a shell are disclosed in U.S. patent application Ser. No.10/056,093, filed on Jan. 28, 2002; the disclosure of which isincorporated herein by reference.

FIG. 60 illustrates a set of membranes for use in constructing a shell2300 of the ear warmer 2000, according to an embodiment of theinvention. The shell 2300 of the ear warmer 2000 includes a first earmembrane 2302, a second ear membrane 2304, a middle membrane 2306, andan outer membrane 2308. The membranes 2302, 2304, 2306, and 2308 can bemade of various types of material appropriate for providing warmth whilealso being comfortable on the wearer's skin. For example, the membranes2302, 2304, 2306, and 2308 can be made of such materials as fleece,wool, cotton, foam and/or neoprene.

In the illustrated embodiment, shell 2300 of the ear warmer 2000 can beconstructed by first disposing first ear membrane 2302 and second earmembrane 2304 on top of outer membrane 2308. Middle membrane 2306 canthen be placed on top of the set of the outer membrane 2308, the firstear membrane 2302, and the second ear membrane 2304 as illustrated inFIG. 61. The ear membranes 2302 and 2304 and the middle membrane 2306are on top of the outer membrane 2308 in the sense that they are orderedin a particular way; the particular orientation of the collection ofmembranes as shown in the figures herein are not important. Thisarrangement of the membranes 2302, 2304, 2306, and 2308 can then becoupled or attached along the perimeter of the shell 2300 via anattachment mechanism, such as an adhesive, a seam, etc.

In one embodiment, this arrangement of the membranes 2302, 2304, 2306,and 2308 is coupled or attached along the perimeter of the shell 2300 ofthe ear warmer 2000 and the perimeter is covered with a binding (notillustrated). In an alternative embodiment for assembling the membranesillustrated in FIG. 61, the middle membrane 2306 can be placed on theouter membrane 2308 and the ear membranes 2302 and 2304 can be placed onthe middle membrane 2306 and the outer membrane 2308.

A variety of couplings or processes can be used to secure the membranes2302, 2304, 2306, and 2308 together. For example, returning to FIG. 61,portions of the ear membranes 2302 and 2304 and middle membrane 2306 canbe bound to outer membrane 2308. Any combination of sewn, bound, or anyother couplings can be used to bind the membranes 2302, 2304, 2306, and2308 to each other. Exemplary methods of assembling the membranes aredisclosed in U.S. Pat. No. 6,332,223 B1, issued on Dec. 25, 2001, thedisclosure of which is hereby incorporated by reference in its entirety.

FIG. 62 illustrates a cross-sectional view of the shell 2300 of FIG. 61taken along the line 62-62. In this embodiment, each membrane 2302,2304, 2306, and 2308 includes a side along a portion of the perimeter ofthat particular membrane. For example, first ear membrane 2302 includesside 2310, second ear membrane 2304 includes side 2312, middle membrane2306 includes sides 2314 and 2316, and outer membrane 2308 includessides 2318 and 2320. The middle membrane 2306 and the outer membrane2308 are disposed proximate to each other so that the middle membranesides 2314 and 2316 are proximate to corresponding sides 2318 and 2320of the outer membrane 2308. Specifically, side 2314 of the middlemembrane 2306 is aligned with side 2318 of the outer membrane 2308.Similarly, side 2316 of the middle membrane 2306 is aligned with side2320 of the outer membrane 2308. The corresponding sides of the othermembranes or membrane portions are placed proximate to each other aswell.

In one embodiment, the sides 2310, 2312, 2314, 2316, 2318, and 2320 ofthe membranes 2302, 2304, 2306, and 2308 as illustrated in FIG. 63 arecoupled together and the membranes are turned inside out as disclosed inU.S. Pat. No. 6,332,223 B1, issued on Dec. 25, 2001; the disclosure ofwhich is incorporated by reference.

A top view of an embodiment of the inverted shell 2300 of an ear warmer2000 is illustrated in FIG. 63. As illustrated, the sides 2310, 2312,2314, 2316, 2318, and 2320 of the membranes 2302, 2304, 2306, and 2308and any coupling of the membranes are not apparent or visible from theexterior of the shell 2300 of the ear warmer 2000 and are located in theinterior region or cavity 2322 of the shell 2300.

FIG. 64 illustrates a cross-sectional view of the shell 2300 of FIG. 63taken along line 64-64. In this embodiment, the corresponding sides ofthe membranes adjacent to each other are fixedly coupled together priorto the membranes being inverted to the positions illustrated in FIG. 64.For example, sides 2314 and 2318 are coupled or bound together to form afixedly coupled portion 2324. Similarly, sides 2316 and 2320 are coupledtogether to form a fixedly coupled portion 2326. The term “fixedlycoupled portion” includes any type of connection or attachment that ifpulled apart would result in damage to the membranes. The ear membranes2302 and 2304 are similarly coupled to the middle membrane 2306 and theouter membrane 2308.

In alternative embodiments, the corresponding sides of the membranesadjacent to each other are removably coupled together. For example, thesides can be removably coupled together using mating connectors, such ashook and loop fasteners, snaps, etc.

In one embodiment, the membranes 2306 and 2308 are coupled together toform fixedly coupled portions 2324 and 2326 using radio frequencywelding. As a result, the fixedly coupled portion 2324 includes a weldthat couples the middle membrane side 2314 and the outer membrane side2318. Similarly, the fixedly coupled portion 2326 includes a weld thatcouples the middle membrane side 2316 and the outer membrane side 2320.In alternative embodiments, the membranes may be coupled together usingany type of welding or any other process that couples the membranestogether.

Once the membranes 2302, 2304, 2306, and 2308 have been coupledtogether, the membranes 2302, 2304, 2306, and 2308 are turned insideout, as described above and as illustrated in FIGS. 63 and 64. Asillustrated, the fixedly coupled portions 2324 and 2326 are disposedwithin the interior region or cavity 2322 of the shell 2300 of the earwarmer 2000.

FIG. 65 illustrates an alternative shell for use in constructing an earwarmer 2000 according to another embodiment of the invention. In thisembodiment, the shell 2350 includes an inner membrane 2352 includes earportions 2354 and 2356, and a middle portion 2358. Outer membrane 2360includes ear portions 2362 and 2364, and a middle portion 2366. Innermembrane 2352 and outer membrane 2360 may be coupled along theperimeters of the membranes 2352 and 2360 to form an inner region orcavity (not illustrated) using any appropriate technology, including,for example, radio frequency welding.

FIG. 66 illustrates a further alternative shell for use in constructingan ear warmer, according to another embodiment of the invention. In thisembodiment, the shell 2370 includes a membrane 2372 having multipleportions. The membrane 2372 includes an outer portion 2374 and a middleportion 2376. The shell 2370 can be arranged as follows. First, earmembranes (e.g., ear membranes 2302 and 2304, not illustrated in FIG.67) can be placed on the corresponding portions 2378 and 2380,respectively, of outer portion 2376. Middle portion 2376 can then befolded on to outer portion 2374 and the ear membranes along the line2382. The collective perimeter can then be bound, welded, or sewn andthe membranes can be turned inside out as described in U.S. Pat. No.6,332,223 B1, issued on Dec. 25, 2001; the disclosure of which isincorporated by reference.

In an alternative embodiment for assembling the shell 2370 illustratedin FIG. 66, the membranes are not turned inside out. For example, themiddle portion 2376 can be folded onto the outer portion 2374 and theear membranes subsequently placed on the outer portion 2374 and themiddle portion 2376. The collective perimeter can then be bound, welded,or sewn.

FIG. 67 illustrates a further alternative shell for use in constructingan ear warmer according to another embodiment of the invention. Theshell 2400 includes a membrane 2402 having a first ear portion 2404, asecond ear portion 2406, a middle portion 2408, and an outer portion2410. The portions 2404, 2406, 2408, and 2410 of the membrane can bearranged as follows. First ear portion 2404 can be folded on to thecorresponding portion 2412 of the outer portion 2410 along line 2416.Similarly, second ear portion 2406 can be folded on to the correspondingportion 2414 of the outer portion 2410 along line 2418. Middle portion2408 can then be folded on to outer portion 2410 and ear portions 2404and 2406 along the line 2420. The collective perimeter can then bebound, welded, or sewn and the membranes 2404, 2406, 2408, and 2410 canbe turned inside out.

In an alternative embodiment for assembling the membranes of FIG. 67,the membranes are not turned inside out. For example, the middle portion2408 can be folded onto the outer portion 2410 along the line 2420. Theear portions 2404 and 2406 can be folded on to the outer portioncorresponding portions 2412 and 2414, respectively. The collectiveperimeter can then be bound, welded, or sewn.

Rather than the separate membranes shown in FIG. 60, variations to FIGS.66 and 67 are possible where certain membranes are integrally (i.e.monolithically) formed together and folded over. For example, in otherembodiments, only one ear membrane is integrally formed with the outermembrane, only two ear membranes are integrally formed with the outermembrane, or only one ear membrane and the middle membrane areintegrally formed with the outer membrane.

In an alternative embodiment, the membranes can be integrally formedtogether at various locations (e.g., discontinuous locations) ratherthan along the entire fold. In another embodiment, the membranes can beintegrally formed at various locations relative to the outer portion ofthe membrane. For example, rather than the ear portions being integrallyformed at the lower location of the outer portion (as shown in FIG. 67),the ear portions can be integrally formed with the outer portion atother locations, such as side locations of the outer portion. Thevarious locations that are possible are those where the portions of themembrane (i.e., the middle portion, and/or the ear portions) fold on tothe outer portion of the membrane to appropriately form the ear warmershell.

While the invention has been described in detail and with references tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope thereof. Thus, it is intended thatthe present invention covers the modifications and variations of thisinvention provided they come within the scope of the appended claims andtheir equivalents. For example, although the fabric member is generallydescribed above as being disposed on the inner side of the ear portionof the frame, the fabric member can instead be disposed on the outerside of the ear frame. In some such embodiments, the fabric member cancover substantially an entirety of the opening on the outer side of theear portion of the frame and less than an entirety of the opening on theinner side of the ear portion of the frame.

1. An ear warmer, comprising: a frame including a band portion and anear portion, the ear portion having an inner side including an innermostsurface along a perimeter of the ear portion, the ear portion includinga first end and a second end, the ear portion having a first portionthat includes the first end and a second portion that includes thesecond end, a length of the first portion of the ear portion beingsubstantially equal to a length of the second portion of the earportion, the first end of the ear portion being coupled to the bandportion, the innermost surface of the ear portion having a proximalportion and a distal portion, the proximal portion of the innermostsurface being included within the first portion of the ear portion, thedistal portion of the innermost surface being included within the secondportion of the ear portion, at least half of the distal portion of theinnermost surface being non-planar when the ear warmer is in an unbiasedcondition.
 2. The ear warmer of claim 1, wherein the band portionincludes a first member and a second member, the first member of theband portion has a first end portion and a second end portion, thesecond end portion of the first member is slidably coupled to the secondmember of the band portion, the ear portion is coupled proximate thefirst end portion of the first member of the band portion.
 3. The earwarmer of claim 1, wherein the ear portion is rotatably coupled to theband portion.
 4. The ear warmer of claim 1, wherein the ear portion istapered from the first end of the ear portion to the second end of theear portion.
 5. The ear warmer of claim 1, wherein a thickness of thefirst end of the ear portion is greater than a thickness of the secondend of the ear portion.
 6. The ear warmer of claim 1, wherein the bandportion has a first member and a second member, the first memberincludes a first end and a second end, the second end of the firstmember is slidably coupled to the second member of the band portion, thefirst member of the band portion has an inner surface and an outersurface, the outer surface of the first member of the band portionincludes a plurality of recesses configured to communicate with an endof the second member of the band portion.
 7. The ear warmer of claim 1,the ear portion including a projection and defining an opening, theprojection extending into the opening, the ear warmer furthercomprising: a molding gate located on the projection.
 8. The ear warmerof claim 1, further comprising: a shell having a cavity, at least aportion of the frame being disposed within the cavity of the shell.9.-17. (canceled)
 18. An ear warmer, comprising: a frame including aband portion and an ear portion, the ear portion including a first endand a second end opposite the first end, the ear portion having a firstportion that includes the first end and a second portion that includesthe second end, the first end of the ear portion being coupled to theband portion, a length of the first portion of the ear portion beingsubstantially equal to a length of the second portion of the earportion, the ear portion having an inner side and an outer side oppositethe inner side, the ear portion having a thickness defined by thedistance between the inner side of the ear portion and the outer side ofthe ear portion, at least a portion of the second portion of the earportion having a thickness of less than 0.06 inches.
 19. The ear warmerof claim 18, wherein the band portion includes a first member and asecond member, the first member of the band portion has a first endportion and a second end portion, the second end portion of the firstmember is slidably coupled to the second member of the band portion, theear portion is coupled proximate the first end portion of the firstmember of the band portion.
 20. The ear warmer of claim 18, wherein theear portion is tapered from the first end of the ear portion to thesecond end of the ear portion.
 21. The ear warmer of claim 18, whereinthe band portion has a first member and a second member, the firstmember includes a first end and a second end, the second end of thefirst member is slidably coupled to the second member of the bandportion, the first member of the band portion has an inner surface andan outer surface, the outer surface of the first member of the bandportion includes a plurality of recesses configured to communicate withan end of the second member of the band portion.
 22. The ear warmer ofclaim 18, the ear portion including a projection and defining anopening, the projection extending into the opening, the ear warmerfurther comprising: a molding gate located on the projection.
 23. Theear warmer of claim 18, further comprising: a shell having a cavity, atleast a portion of the frame being disposed within the cavity of theshell.
 24. A frame of an ear warmer, comprising: a band portion; and anear portion coupled to the band portion, the ear portion having acoupling portion coupled to the band portion, a first projecting portioncoupled to the coupling portion, a second projecting portion coupled tothe coupling portion, and an extension portion, the extension portionhaving a first end and a second end opposite the first end of theextension portion, the first end of the extension portion being coupledto the first projecting portion, the second end of the extension portionbeing coupled to the second projecting portion, the extension portionhaving an inner side that includes an innermost surface along aperimeter of the extension portion, the innermost surface of theextension portion having a non-planar shape when the frame is in anunbiased condition.
 25. The frame of claim 24, wherein the band portionincludes a first member and a second member, the first member of theband portion has a first end portion and a second end portion, thesecond end portion of the first member is slidably coupled to the secondmember of the band portion, the ear portion is coupled proximate thefirst end portion of the first member of the band portion.
 26. The frameof claim 24, wherein the band portion has a first member and a secondmember, the first member includes a first end and a second end, thesecond end of the first member is slidably coupled to the second memberof the band portion, the first member of the band portion has an innersurface and an outer surface, the outer surface of the first member ofthe band portion includes a plurality of recesses configured tocommunicate with an end of the second member of the band portion. 27.The frame of claim 24, the ear portion including a projection anddefining an opening, the projection extending into the opening, the earwarmer further comprising: a molding gate located on the projection. 28.The frame of claim 24, further comprising: a shell having a cavity, atleast a portion of the frame being disposed within the cavity of theshell. 29.-31. (canceled)
 32. The ear warmer of claim 1, wherein thefirst portion of the ear portion is curved about a first axis, the firstaxis is substantially orthogonal to a longitudinal plane of the earportion, the second portion of the ear portion is curved about a secondaxis, the second axis is substantially orthogonal to the longitudinalplane of the ear portion, the second axis is spaced apart from the firstaxis, and each of the first axis and the second axis is spaced apartfrom and extends along an inner side of the ear portion.